Aigat : Automatic winding scheme for photovoltaic inverters and energy storage inductors

AJT focuses on the field of green energy, providing high-tension and compact automatic winding solutions for core components such as high-power inductors and inverter transformers. Combined with the self-developed vertical/horizontal winding control system and precision shaping patents, it overcomes the problem of large-diameter winding and deformation and helps the energy storage system achieve high-efficiency transformation.

1. Industry trends: process challenges under high voltage and high current In the context of the "dual carbon" strategy, photovoltaic inverters and energy storage systems (ESS) are rapidly iterating in the direction of high voltage and high power. As the core inductive components of energy conversion, high-power inductors and transformers need to carry larger currents, which puts forward strict requirements for the wire diameter, temperature rise control and package size of the coil. When dealing with large diameter flat wires, traditional equipment often faces technical bottlenecks such as large tension fluctuations, tight wire arrangements, and coil rebound deformation. With its sophisticated mechanical structure and intelligent control algorithms, AJT provides an automated production base with excellent performance for the photovoltaic and energy storage industries.

2. Technical barriers: combining software and hardware to solve the problem of thick wire winding Eggart aims at the structural characteristics of photovoltaic energy storage coils and uses a number of core technologies approved in 2024 to empower the process:

Powerful shaping and cornering technology: Application of "a corner folding device for flat wires" and "a coil shaping device" (patent number: ZL 2023 2 2778193.0). For large-section cables, the reinforced servo drive mechanism ensures that accurate corner bending and tight stacking can still be achieved under high tensile force, effectively suppressing coil rebound and optimizing heat dissipation space.

Self-developed control system core: Equipped with the company's self-developed "automatic flat coil double winding machine control system" (software registration number: 2024SR1172274). The system has excellent low-speed and high-torque control capabilities, realizing microsecond speed compensation at winding corners, ensuring that the wiring is as neat as a "shingle", effectively improving the slot full rate and obtaining better heat dissipation performance.

High reliability verification: Combined with the patent of the coil parameter inspection tool, the geometric size of the finished inductor is dynamically monitored to ensure that each module can maintain stable electrical performance in the harsh outdoor energy storage environment.

3. Application Fields and Customer Value This solution focuses on: photovoltaic inverter step-up inductors, energy storage bidirectional converter (PCS) inductors, high-power filter coils and high-frequency transformers. The adoption of the Eggart solution can not only greatly reduce the strength and error of manual winding, but also improve production efficiency while reducing the resistance loss of the coil, and contribute to the efficient storage and transformation of global zero-carbon energy.