CN103930958A - 用于分裂铁芯构造的缠绕式铁芯制造方法 - Google Patents

用于分裂铁芯构造的缠绕式铁芯制造方法 Download PDF

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CN103930958A
CN103930958A CN201280055682.5A CN201280055682A CN103930958A CN 103930958 A CN103930958 A CN 103930958A CN 201280055682 A CN201280055682 A CN 201280055682A CN 103930958 A CN103930958 A CN 103930958A
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R·M·帕里什
F·P·伯克
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Hitachi Energy Co ltd
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Abstract

一种通过经由提供变压器铁芯材料形成铁芯来提供变压器的一部分的方法：切割单个叠片并且将它们弯曲成大体上C形件；堆叠一些构件以限定具有主要支腿与两个相对端部支腿的第一铁芯部分；堆叠其他构件中以限定具有主要支腿与两个相对端部支腿的第二铁芯部分；以背对背的方式布置主要支腿以限定具有由所述两个主要支腿限定的铁芯支腿以及由所述端部支腿限定的相对的铁芯轭的铁芯。导电材料直接地缠绕在铁芯支腿周围以便以任何布置的顺序形成初级绕组与次级绕组，由此提供第一变压器部分。变压器部分可以是单个变压器的一部分，或者当提供第二变压器部分与第三变压器部分时，作为三相变压器的一部分。

Description

用于分裂铁芯构造的缠绕式铁芯制造方法
技术领域
本发明涉及功率分配变压器，并且更具体地说，涉及制造具有直接卷绕于其上的初级与次级绕组的分裂铁芯构造的方法。
背景技术
传统地，铁芯制造过程以及用于分配变压器的绕组制造过程是分开的，铁芯与绕组在后面阶段装配在一起。为方便此，铁芯与绕组制造成一组标准尺寸以简化制造并且减少要求的铁芯加工的量。由于此标准化，因此不能充分地优化铁芯与绕组构造。这导致成本增加并且丧失竞争力。
因此，需要以类似的输出速度为现有的缠绕铁芯技术提供完全灵活的铁芯构造。
发明内容
本发明的一个目的是实现上述需要。根据实施方式的原理，通过提供变压器的一部分的方法实现了此目的。此方法通过以下形成变压器的铁芯：提供变压器铁芯材料；切割单个叠片并且将它们弯曲成大体上C形件；堆叠所述构件中的一部分以限定具有主要支腿与两个相对端部支腿的第一铁芯部分；堆叠所述构件中的其它部分以限定具有主要支腿与两个相对端部支腿的第二铁芯部分；以背对背的方式布置主要支腿以限定具有通过两个主要支腿限定的铁芯支腿以及通过端部支腿限定的铁芯轭的铁芯。导电材料直接地缠绕在铁芯支腿周围以便以任何布置的顺序形成初级绕组与次级绕组，由此提供第一变压器部分。第一变压器部分可以是单个变压器的一部分，或者当提供第二变压器部分与第三变压器部分时，作为三相变压器的一部分。
当参照其全部形成此说明书的一部分的附图考虑下面的详细描述与所附权利要求时，本发明的其它目的、特征与特点、以及操作的方法以及结构的相关元件的功能、部件的组合和制造经济性将变得更加显而易见。
附图说明
通过本发明的优选实施方式的下面的详细描述，结合附图将会更好地理解本发明，其中相同附图标记指示相同部件，其中：
图1是根据实施方式的提供的变压器的一部分的视图。
图2是图1的变压器部分的铁芯部分的视图。
图3是图1的变压器部分的铁芯的视图。
图4是根据实施方式的与绝缘层缠绕在一起的导电片的视图。
图5是实施方式的单相变压器的视图。
图6是根据提供三相变压器的实施方式的耦合到另一个变压器部分的一个变压器部分的视图。
图7是实施方式的三相变压器的视图。
具体实施方式
本实施方式涉及用于单相与三相铁芯与壳式分布变压器的制造方法。因此，参照图1，示出了大体上以10指示的单相变压器的一部分的立体图，包括根据本发明体现的大体上以12指示的铁芯构造。如下面说明的，铁芯12包括两个铁芯部分16和18。变压器部分10包括安装到铁芯12的绕组组件14。
参照图2，为形成每个铁芯部分16和18，首先提供诸如一片铁磁金属的变压器铁芯材料。从铁芯材料切下单个叠片20。每个叠片20都弯曲成大体上C形并且这些叠片20中的一部分堆叠以限定具有主要支腿22与两个相对端部支腿24、26的第一铁芯部分16。主要支腿22具有后表面27。其它叠片20堆叠以限定具有主要支腿28与两个相对端部支腿30、32的第二铁芯部分18。主要支腿28具有后表面29。
参照图3，各个主要支腿22和28的后表面27和29布置为以背对背方式接触以限定具有铁芯支腿34和相对的铁芯轭的铁芯12，铁芯支腿34通过两个主要支腿22、28限定，相对的铁芯轭大体上以36和38指示，轭26通过端部支腿24与30限定并且轭38通过端部支腿26和32限定。后表面27与29可以耦合或连接。铁芯12优选地形成在通过修改其编程由AEM统一接口项目(Unicore)制造的统一接口项目(Unicore)生产机器上，或者通过特别地构造用于形成铁芯12的机器形成。
在形成铁芯12以后，铁芯12移动到绕线机并且诸如铜的导电材料直接地缠绕在铁芯支腿34周围以限定绕组组件14(图1)。特别地，绕组组件14包括低电压绕组44与高电压绕组46。可以使用两个单独的机器来缠绕低电压绕组44与高电压绕组46。另选地，可以使用单个、组合机器来缠绕两个绕组44、46。
如图1和图3中最佳示出的，在轭36和38的端部42中设有狭缝40以方便引导铁芯12的绕组以便如将在下面描述的形成变压器。狭缝40限定在相对于铁芯支腿34的轴A的横向方向延伸的交替的切口与突出部52(图3)。因此，将狭缝40移动到轭允许直接地在铁芯支腿34上缠绕。如果狭缝40位于常规位置中，此缠绕是不可能的。
将低压绕组44缠绕在机器上的实例如下：
1)调节铁芯夹紧工具以容纳正确尺寸的铁芯12使得以接触背对背的方式夹紧所述主要支腿22和28；
2)将铁芯12安装到绕线机；
3)选择与加载正确的导电材料与绝缘材料；
4)为特定的铁芯低压绕组构造将该机器编程以多个转/层；
5)通过附接第一汇流排开始处理；
6)通过同时地缠绕导电材料47与绝缘材料49(图4)而开始绕线(如在美国专利No.6,221,297中公开的，在此其内容通过引用的方式包含在此说明书中)；
7)贯穿绕线过程如需要的话插入冷却导管48(图1)与绝缘屏障；
8)在适当程序位置附接第二汇流排；
9)最终完成低压绕组44并且用带子将其固定；以及
10)将具有低压绕组44的铁芯12从机器移除(如果使用单独的绕线机)。
如果使用两个绕线机，具有低压绕组44的铁芯12然后移动到高压绕线机并且高压绕组46的缠绕如下：
1)调节铁芯夹紧工具以容纳正确尺寸的铁芯12；
2)将铁芯12(现在具有低压绕组44)安装到机器；
3)选择与加载正确的导体材料与绝缘体；
4)为特定设计编程该机器以多个转/层；
5)开始在低压绕组44上方绕线(如上所述导电材料与绝缘材料同时地)；
6)贯穿绕线过程如需要的话插入冷却导管与绝缘屏障；
7)如要求的在适当的编程位置建立电分接点；
8)最终完成低压绕组46并且用带子将其固定；
9)将具有绕组44、46的铁芯12从机器移除。
在此实施方式中，应该注意的是高压绕组46缠绕在低压绕组44上。然而，只要形成至少初级与次级绕组，那么绕线的顺序与绕组的数量就是不重要的。如果变压器是降压变压器，那么高压绕组46就是初级绕组并且低压绕组44是次级绕组。另选地，如果变压器是升压变压器，那么高压绕组46就是次级线圈并且低压绕组44是初级绕组。
参照图5，为了完成大体上以45指示的单相变压器，利用C形侧支腿50的端部限定的、与轭36、38的端部支腿的狭缝40和突出部配合的狭缝40和突出部52将C形侧支腿50(参见图6)耦合到轭36、38。参照图6和图7最佳解释侧支腿50的装配，其中形成大体上以51指示的三相变压器。参照图6，通过上述方法形成了三个变压器部分。图6中示出的两个变压器部分10和10’，准备耦合在一起。因此，变压器部分10’被移动从而铁芯部分16’的端部支腿中的突出部52’与变压器部分10的铁芯部分18的端部支腿中的狭缝40接合，并且变压器部分10的铁芯部分18的端部支腿的突出部52与变压器部分10’的铁芯部分16’的端部支腿中的狭缝40’接合。如图7中示出的，第三变压器部分10”以相同的方式耦合到变压器部分10的铁芯部分16的端部支腿。最后，利用其狭缝以及相关的突出部将同样具有狭缝40与突出部52的C形侧支腿50，耦合到变压器部分10’的铁芯部分18’并且耦合到变压器部分10”的铁芯部分16”。
通过实施方式的方法，在制造铁芯12以后绕组44和46直接地缠绕在铁芯支腿34上以减少制造时间。此方法还允许完全地优化铁芯12与绕组构造以降低材料成本。还能够利用此铁芯制造的方法消除铁芯退火处理。此方法还显著地提高了制造吞吐量、减少了劳动力、提高了质量、并且降低了OHS风险。此方法允许用于利用缠绕铁芯技术传统地制造的变压器的缠绕铁芯(WOC)支腿。
为了描述本发明的结构与功能原理的目的已经示出且描述了上述优选实施方式，并且描述了利用优选实施方式的方法并且在不偏离此原理的情况下可以进行改变。因此，本发明包括包含在下面权利要求的精神内的全部修改。

Claims (10)

1.一种提供变压器的一部分的方法，包括：
通过以下形成所述变压器的铁芯：
提供变压器铁芯材料；
切割各个叠片并且将它们弯曲成大体上C形构件；
堆叠所述构件中的一部分以限定具有主要支腿与两个相对端部支腿的第一铁芯部分；
堆叠所述构件中的其它部分以限定具有主要支腿与两个相对端部支腿的第二铁芯部分；
以背对背的方式布置所述主要支腿以限定具有由所述两个主要支腿限定的铁芯支腿以及由所述端部支腿限定的相对的铁芯轭的铁芯，以及
将导电材料直接地缠绕在所述铁芯支腿周围以便以任何布置的顺序形成初级绕组与次级绕组，由此提供第一变压器部分。
2.根据权利要求1所述的方法，其中所述提供变压器铁芯材料的步骤提供铁磁金属片。
3.根据权利要求1所述的方法，其中在缠绕所述低压绕组的步骤以前，所述方法包括将所述主要支腿夹紧以便成接触背对背关系。
4.根据权利要求1所述的方法，其中在缠绕所述低压绕组的步骤期间，在所述低压绕组中设有冷却导管。
5.根据权利要求1所述的方法，其中在缠绕所述高压绕组的步骤期间，在所述高压绕组中设有冷却导管。
6.根据权利要求1所述的方法，其中缠绕所述导电材料以限定所述初级绕组与所述次级绕组的步骤包括与绝缘材料同时地缠绕所述导电材料。
7.根据权利要求1所述的方法，还包括：
提供一对大体上C形的侧支腿，
将一个侧支腿耦合到所述第一铁芯部分的所述端部支腿，并且
将另一个侧支腿耦合到所述第二铁芯部分的所述端部支腿由此限定在单相变压器中。
8.根据权利要求7所述的方法，其中所述耦合步骤包括将所述侧支腿中的突出部与所述端部支腿中的狭缝接合以及将所述端部支腿中的突出部与所述侧支腿中的狭缝接合。
9.根据权利要求1所述的方法，还包括：
以与所述第一铁芯部分相同的方式提供第二变压器部分与第三变压器部分；
将所述第二变压器部分的所述第一铁芯部分的端部支腿耦合到所述第一变压器部分的所述第二铁芯部分的所述端部支腿，
将所述第三变压器部分的所述第二铁芯部分的端部支腿耦合到所述第一变压器部分的所述第一铁芯部分的所述端部支腿；
将第一C形侧支腿耦合到所述第二变压器部分的所述第二铁芯部分的所述端部支腿；以及
将第二C形侧支腿耦合到所述第三变压器部分的所述第一铁芯部分的所述端部支腿以限定三相变压器。
10.根据权利要求9所述的方法，其中耦合所述端部支腿的步骤包括将所述第一变压器部分的所述端部支腿中的突出部与所述第二变压器部分与第三变压器部分中的每个的所相关端部支腿中的狭缝接合，以及将所述第二变压器部分与第三变压器部分中的每个的所述端部支腿中的突出部与所述第一变压器部分的所述端部支腿中的相关狭缝接合，并且
其中耦合所述C形侧支腿的步骤包括将所述第一C形侧支腿中的突出部与所述第二变压器部分的所述端部支腿中狭缝接合，以及将所述第二变压器部分的所述端部支腿中的突出部与所述第一C形侧支腿中的狭缝接合，以及
将所述第二C形侧支腿中的突出部与所述第三变压器部分的所述端部支腿中的狭缝接合，并且将所述第三变压器部分的所述端部支腿中的突出部与所述第二C形侧支腿中的狭缝接合。
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