Transformer winding machine tension factors affecting the size of the coil

Transformer winding machines are made of wire winding. The conductors are copper conductors and aluminum conductors, and each layer of conductors is covered with different types of insulation layers, i.e., the conductors are directly combined with various insulation layers to form a whole, and the role of these insulation layers is to constitute the inter-turn insulation for winding.
The coil we usually use is a single paper wrapped flat aluminum wire with a wire gauge of 2.2*2.5mm continuously wound to form a single pie type coil. Traction transformer pie coils need to meet the technical requirements in terms of size, tightness and flatness.
Coil winding, wire gauge and inter-turn gap determine the size of the coil, the prerequisite for controlling the coil size is to find out the factors affecting the coil turn gap, which is also necessary to control the coil size.

1, the coil size problem
Recently, when using a vertical transformer winding machine to wind a single pancake coil, the magnetic powder clutch current value of the winding machine to control the tension is set to 0.45A, the coil winding is completed after the B-end size are large, beyond the range of process requirements.
2, the coil size problem cause analysis
When the vertical winding machine tension-related current value is set to 0.45A, the winding process found that the tension is too small, resulting in uneven force on the wire on the coil, when the coil rotates due to inertia coil idle phenomenon, the wire off more, resulting in the wire between the coil and the wire clamping device is not the ideal horizontal state, but sagging out of a certain arc, so the wire in the winding process force is not Uniformity, and the winding of the completed line cake tightness is not enough, resulting in the coil B size is greater than the technical requirements.
3, magnetic ring winding machine tension and coil size relationship analysis
(1) the appropriate increase in winding machine tension on the impact of the coil. In the coil winding process, gradually increase the tension, adjust the tension-related current value of the vertical winding machine to 0.46A, the coil slack. The phenomenon of large size was improved, but still did not meet the requirements.
Continue to increase the tension of the vertical winding machine to adjust the current value to 0.47A, the coil size meets the requirements, and the coil is tight, no obvious gap in the A, B end, the four corners are not taut or upward phenomenon, the wire gauge changes in line with the requirements.
(2) winding machine pulling force is too large for the impact of the coil. Continue to increase the vertical winding machine tension-related current value to 0.51A, the coil in the winding process, the 4 corners of the force is too heavy, there is the phenomenon of upturn, after the completion of winding, the wire asked no obvious gap, the wire gauge does not sharply reduce, but the 4 corners of the phenomenon of upturn, does not meet the technical requirements.
It can be seen from the above, when the vertical winding machine tension value is too small, the coil winding is completed, the coil is small and tight, the wire asks a gap, and the B-end size is greater than the technical requirements. Appropriate increase in the vertical winding machine tension can reduce the size of the B end of the wire cake, and small impact on the wire gauge, so as to improve the size of the B end of the problem is large. However, when the vertical winding machine tension is too large, and will lead to small coils in line with technical requirements.

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