The winding quality of cast resin distribution transformers directly affects their insulation reliability and operational stability—core requirements include uniform, tight wiring without knots, crossings, or overlaps, with standardized parallel winding for multi-wire configurations. Below is a systematic breakdown of key winding rules and classification.
1. Core Winding Requirements
(1) Basic Wiring Standards
- Uniform and tight winding: Wire spacing is roughly equal, and the entire winding area is fully covered.
- No defects: No knots, no cross-wiring, no overlaps, and the upper layer does not sink into the lower layer.
- End control tape compliance: Windings must be close to the end control tape but must not exceed it (avoids insulation gaps or structural instability).
(2) Parallel Winding Specifications
- When using two or more wires for the same group, they must be wound in parallel simultaneously.
- Parallel wires must not cross each other—ensures consistent current distribution and avoids local overheating.
2. Classification of Winding Methods
Based on the number of wire groups and winding combinations, the methods are divided into four types:
| Winding Type | Core Description | Application Scenario |
|---|---|---|
| a. Same group, same winding | Multiple wires of the same group are wound in parallel as a single unit. | Small-to-medium capacity transformers (requires consistent wire parameters). |
| b. Different groups, parallel winding | Wires from different groups are wound in parallel, with clear group separation. | Transformers needing independent winding branches (e.g., multi-tap transformers). |
| c. Multiple groups, parallel winding | Three or more groups of wires are wound in parallel, maintaining group integrity. | Large-capacity transformers requiring balanced load distribution. |
| d. Double winding (same/different groups) | Two sets of windings (either same or different groups) are wound in parallel, with separate insulation. | Transformers with dual output requirements or redundant design. |
3. Critical Operational Notes
- Dense winding requirement: For single-layer dense winding, no second layer is allowed until the entire layer is fully wound; no gaps or crossings between wires.
- Winding centerline protection: The centerline of the winding must not be layered or crossed—ensures uniform magnetic field distribution and mechanical strength.
- Consistency control: Parallel wires must have the same diameter, material, and insulation level to avoid uneven current-carrying and partial discharge.
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