CN109148100B - Ultrahigh and oversized nanocrystalline magnetic core and manufacturing method thereof - Google Patents
Ultrahigh and oversized nanocrystalline magnetic core and manufacturing method thereof Download PDFInfo
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- CN109148100B CN109148100B CN201810917147.5A CN201810917147A CN109148100B CN 109148100 B CN109148100 B CN 109148100B CN 201810917147 A CN201810917147 A CN 201810917147A CN 109148100 B CN109148100 B CN 109148100B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/25—Magnetic cores made from strips or ribbons
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
- H01F27/263—Fastening parts of the core together
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F38/00—Adaptations of transformers or inductances for specific applications or functions
- H01F38/20—Instruments transformers
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- H—ELECTRICITY
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0213—Manufacturing of magnetic circuits made from strip(s) or ribbon(s)
- H01F41/0226—Manufacturing of magnetic circuits made from strip(s) or ribbon(s) from amorphous ribbons
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Abstract
The invention discloses an ultrahigh and oversized nanocrystalline magnetic core, which comprises a magnetic core body, wherein the magnetic core body comprises a stainless steel protective box, a cover plate and a plurality of short magnetic cores, the height of the magnetic core body is 68-162 mm, the outer diameter of the magnetic core body is 512-1220 mm, the inner diameter of the magnetic core body is 388-980 mm, the weight of the magnetic core body is 38-178 kg, the short magnetic cores are made of iron-based nanocrystalline soft magnetic alloy, the height of the short magnetic cores is 20-30mm, the short magnetic cores are mutually insulated, the initial permeability of the magnetic core body is more than 8 ten thousand, the net height ratio of the magnetic core body is more than 88%, the magnetic core body is made of the iron-based nanocrystalline soft magnetic alloy, and the ultrahigh and oversized nanocrystalline magnetic core is manufactured by adopting the. The invention realizes the movable stacking of large-size magnetic cores after annealing by a special stacking and assembling technology, the large-size magnetic cores are placed in the same protective box, the magnetic cores are insulated, the magnetic conductivity is not reduced, and the ultrahigh and ultra-large-size iron-based nanocrystalline alloy magnetic core with high magnetic conductivity is obtained.
Description
Technical Field
The invention belongs to the technical field of mutual inductor magnetic cores, and particularly relates to an ultrahigh and oversized iron-based nanocrystalline alloy magnetic core and a manufacturing method thereof.
Background
The iron-based nanocrystalline magnetically soft alloy has an ultrahigh initial permeability and an extremely low magnetic core loss, and is widely applied to the field of high-precision transformers. The iron-based nanocrystalline alloy is an alloy with a nanocrystalline and amorphous dual-phase structure obtained by crystallizing and annealing amorphous alloy, the nanocrystalline alloy magnetic core is generally obtained by winding an amorphous alloy thin strip and then performing crystallization and annealing in a vacuum furnace, and the density of the nanocrystalline alloy is higher than that of the amorphous alloy, so that the magnetic core can shrink by about 4% in the crystallization and annealing process. If the core size is too large, once the core is amorphous, the heat release is not uniform, even if the whole furnace temperature is consistent, the temperature difference among the parts of the core is large, the contraction of the core is different, the phenomena of surface corrugation and edge curling of the core are generated, and the magnetic permeability of the core is obviously reduced, so the outer diameter of the existing nanocrystalline alloy core is generally less than 500mm, and the height is less than 60 mm.
With the development of the field of high-voltage transformers, the industry has put forward the requirements for manufacturing higher and larger nanocrystalline alloy magnetic cores. The width of the amorphous ribbon for the nanocrystalline is generally not more than 60mm, but the amorphous ribbon with the thickness of 20-30mm is most easily manufactured. The high permeability nanocrystalline alloy magnetic core prepared after annealing is particularly sensitive to stress and generally needs to be arranged in a protective box to realize moving and stacking, and for an ultra-large magnetic core, if the protective box is not arranged, the movement is difficult to realize. Nanocrystalline alloy magnetic cores having heights in excess of 60mm are typically manufactured by first fabricating a plurality of relatively short magnetic cores, each of which is placed in a protective casing, and then stacking and assembling the casings containing the magnetic cores together to form an ultra-high magnetic core. Because the protective box has a certain thickness, a certain gap is required to be left between the magnetic core and the protective box, so that the net height ratio of the magnetic core (namely the ratio of the net height to the total height) is less than 82%, the waste of space is caused, and the amount of wound copper wires is increased when the mutual inductor is manufactured. In view of this, there is a need for improvements to conventional ultra-high oversized nanocrystalline cores.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide an ultrahigh and oversized nanocrystalline magnetic core and a manufacturing method thereof.
In order to achieve the above object, the present invention adopts the following technical solutions:
the utility model provides an ultrahigh super large nanocrystalline magnetic core, includes the magnetic core body, and the magnetic core body includes that stainless steel protects box, apron and a plurality of short magnetic core, and the height of magnetic core body is 68~162mm, and the external diameter is 512~1220mm, and internal diameter 388~980mm, weight are 38~178 kilograms.
Preferably, the initial permeability of the aforementioned magnetic core body is greater than 8 ten thousand.
Preferably, the short magnetic cores are made of iron-based nanocrystalline magnetically soft alloy, the height of the short magnetic cores is 20-30mm, and the short magnetic cores are insulated from each other.
More preferably, the net height ratio of the aforementioned magnetic core body is greater than 88%.
Further preferably, the method for manufacturing the ultra-high and ultra-large iron-based nanocrystalline alloy magnetic core includes the following steps:
s1, preparing an amorphous thin belt by adopting a single-roller melt-spun method;
s2, winding the amorphous thin coil into an annular short magnetic core;
s3, carrying out crystallization annealing treatment on the short magnetic core in a vacuum environment, cooling, removing vacuum, and discharging;
s4, uniformly coating a layer of silicon rubber on the bottom of the stainless steel protective box, sucking up the short magnetic core by adopting an electromagnet with the shape consistent with the end face of the short magnetic core, and lightly putting the short magnetic core on the silicon rubber layer in the stainless steel protective box;
s5, uniformly coating a layer of silicon rubber on the other end face of the placed short magnetic core, sucking up the second short magnetic core by adopting an electromagnet with the shape consistent with that of the end face of the short magnetic core, and moving and stacking the second short magnetic core on the first short magnetic core;
s6, repeating the step S5 until the short magnetic core in the stainless steel protective box reaches the required height;
s7, uniformly coating a layer of silicon rubber on the end face of the short magnetic core at the topmost layer, filling the silicon rubber in a gap between the short magnetic core and the stainless steel protective box, and covering a cover plate after the silicon rubber is dried completely to obtain the nanocrystalline alloy magnetic core product.
Preferably, in step S1, the amorphous ribbon has a thickness of 30 ± 2 μm and a width of 20 to 30 mm.
Still preferably, in step S2, the winding mold is made of wood.
More preferably, in step S3, the conditions of the crystallization annealing process are: preserving heat for 120-180 min at 465-475 ℃, then heating to 540-550 ℃, and preserving heat for 150-180 min.
Further preferably, the temperature rise rate during the temperature rise to 540 to 550 ℃ is less than 0.3 ℃/min.
Specifically, in the foregoing steps S4 and S5, the electromagnet end faces are made of electrical pure iron.
The invention has the advantages that:
(1) according to the invention, by controlling slow and uniform release of latent heat of the amorphous, the influence of volume shrinkage on soft magnetic performance during amorphous crystallization is slowed down, and the ultra-large nanocrystalline magnetic core with the outer diameter of 500-1200 mm can be manufactured, and the initial magnetic permeability of the magnetic core reaches more than 8 ten thousand;
(2) the manufacturing requirements of the super-large high-voltage transformer can be met through a movable stacking system, and the ratio of the net height to the total height of the manufactured super-high super-large nanocrystalline magnetic core is more than 88 percent and is better than 82 percent of the current magnetic core;
(3) the manufactured ultra-high and ultra-large nanocrystalline magnetic core only needs one stainless steel protective box, so that stainless steel materials are saved;
(4) the ultra-large magnetic core can be uniformly absorbed by the electromagnet and is not deformed, so that the ultra-large nanocrystalline magnetic core can be movably stacked after annealing, and the initial magnetic permeability is not reduced basically.
Drawings
Fig. 1 is a cross-sectional view of an ultra-high oversized iron-based nanocrystalline alloy magnetic core in an embodiment of the invention.
The meaning of the reference symbols in the figures: 1. stainless steel protects the box, 2, short magnetic core, 3, apron.
Detailed Description
The invention is described in detail below with reference to the figures and the embodiments.
Example 1
The utility model provides an ultra-high super large nanocrystalline magnetic core, includes the magnetic core body, and the magnetic core body includes that the stainless steel protects box 1, apron 3 and 4 short magnetic cores 2, and the height of magnetic core body is 130mm, and the external diameter is 815mm, and the internal diameter is 585mm, and weight is 178 kilograms. The short magnetic cores 2 are made of iron-based nanocrystalline soft magnetic alloy, the height of the short magnetic cores is 30mm, and the short magnetic cores 2 are insulated from each other. The stainless steel protective box 1 is made of 304 stainless steel, and has the dimensions of 815mm of outer diameter, 585mm of inner diameter, 127.5mm of height and 2.5mm of wall thickness. The cover plate 3 is annular, the outer diameter is 815mm, the inner diameter is 585mm, the thickness is 2.5mm, and the material is epoxy resin.
A manufacturing method of an ultra-high and ultra-large iron-based nanocrystalline alloy magnetic core comprises the following steps:
s1, preparing an amorphous thin belt by a single-roller melt-spinning method, wherein the thickness of the amorphous thin belt is 30 +/-2 microns, and the width of the amorphous thin belt is 30 mm;
s2, winding the amorphous thin coil into an annular short magnetic core 2, wherein the size of the annular magnetic core is 820mm in outer diameter, 620mm in inner diameter and 30mm in height, and the winding mold is made of wood;
s3, carrying out crystallization annealing treatment on the short magnetic core 2 in a vacuum environment, preserving heat for 180min at 470 ℃, then heating to 540 ℃ at the speed of 0.3 ℃/min, preserving heat for 180min, removing vacuum after cooling, and discharging; (ii) a The dimensions of the cooled annular magnetic core are about 800mm of outer diameter, 600mm of inner diameter and 30mm of height;
s4, uniformly coating a layer of silicon rubber on the bottom of the stainless steel protective box 1, sucking up the short magnetic core 2 by adopting an electromagnet with the shape consistent with the end face of the short magnetic core 2, and lightly putting the short magnetic core 2 on the silicon rubber layer in the stainless steel protective box 1; the end face of the electromagnet is made of electrician pure iron;
s5, uniformly coating a layer of silicon rubber on the other end face of the placed short magnetic core 2, sucking up the second short magnetic core 2 by adopting an electromagnet with the shape consistent with that of the end face of the short magnetic core 2, and moving and stacking the second short magnetic core 2 on the first short magnetic core 2;
s6, repeating the step S5 until the short magnetic core 2 in the stainless steel protective box 1 reaches the required height;
s7, uniformly coating a layer of silicon rubber on the end face of the short magnetic core 2 at the topmost layer, filling the silicon rubber in the gap between the short magnetic core 2 and the stainless steel protective box 1, and covering the cover plate 3 after the silicon rubber is dried completely to obtain the nanocrystalline alloy magnetic core product.
Example 2
The utility model provides an ultra-high super large nanocrystalline magnetic core, includes the magnetic core body, and the magnetic core body includes that the stainless steel protects box 1, apron 3 and 5 short magnetic cores 2, and the height of magnetic core body is 162mm, and the external diameter is 512mm, internal diameter 388mm, weight 74.7 kilograms. The short magnetic cores 2 are made of iron-based nanocrystalline soft magnetic alloy, the height of the short magnetic cores is 20-30mm, and the short magnetic cores 2 are insulated from each other. The stainless steel protective box 1 is made of 304 stainless steel, and has the dimensions of 512mm external diameter, 388mm internal diameter, 159.5mm height and 2.5mm wall thickness. The cover plate 3 is annular, the outer diameter is 512mm, the inner diameter is 388mm, the thickness is 2.5mm, and the material is epoxy resin.
A manufacturing method of an ultra-high and ultra-large iron-based nanocrystalline alloy magnetic core comprises the following steps:
s1, preparing an amorphous thin belt by a single-roller melt-spinning method, wherein the thickness of the amorphous thin belt is 30 +/-2 microns, and the width of the amorphous thin belt is 20-30 mm;
s2, winding the amorphous thin coil into an annular short magnetic core 2, wherein the size of the annular short magnetic core 2 is 512mm in outer diameter, 412mm in inner diameter and 30mm in height, and the winding mold is made of wood;
s3, carrying out crystallization annealing treatment on the short magnetic core 2 in a vacuum environment, preserving heat at 475 ℃ for 120min, then heating to 550 ℃ at the speed of 0.3 ℃/min, preserving heat for 150min, cooling, removing vacuum, and discharging;
s4, uniformly coating a layer of silicon rubber on the bottom of the stainless steel protective box 1, sucking up the short magnetic core 2 by adopting an electromagnet with the shape consistent with the end face of the short magnetic core 2, and lightly putting the short magnetic core 2 on the silicon rubber layer in the stainless steel protective box 1; the end face of the electromagnet is made of electrician pure iron;
s5, uniformly coating a layer of silicon rubber on the other end face of the placed short magnetic core 2, sucking up the second short magnetic core 2 by adopting an electromagnet with the shape consistent with that of the end face of the short magnetic core 2, and moving and stacking the second short magnetic core 2 on the first short magnetic core 2;
s6, repeating the step S5 until the short magnetic core 2 in the stainless steel protective box 1 reaches the required height;
s7, uniformly coating a layer of silicon rubber on the end face of the short magnetic core 2 at the topmost layer, filling the silicon rubber in the gap between the short magnetic core 2 and the stainless steel protective box 1, and covering the cover plate 3 after the silicon rubber is dried completely to obtain the nanocrystalline alloy magnetic core product.
Example 3
The utility model provides an ultra-high super large nanocrystalline magnetic core, includes the magnetic core body, and the magnetic core body includes that the stainless steel protects box 1, apron 3 and 2 short magnetic cores 2, and the height of magnetic core body is 68mm, and the external diameter is 1220mm, and internal diameter 980mm, weight are 157.46 kilograms. The short magnetic cores 2 are made of iron-based nanocrystalline soft magnetic alloy, the height of the short magnetic cores is 30mm, and the short magnetic cores 2 are insulated from each other. The stainless steel protective box 1 is made of 304 stainless steel, and has the size of 1220mm of outer diameter, 980mm of inner diameter, 65.5mm of height and 2.5mm of wall thickness. The cover plate 3 is annular, the outer diameter is 1220mm, the inner diameter is 980mm, the thickness is 2.5mm, and the material is epoxy resin.
A manufacturing method of an ultra-high and ultra-large iron-based nanocrystalline alloy magnetic core comprises the following steps:
s1, preparing an amorphous thin belt by a single-roller melt-spinning method, wherein the thickness of the amorphous thin belt is 30 +/-2 microns, and the width of the amorphous thin belt is 30 mm;
s2, winding the amorphous thin coil into an annular short magnetic core 2, wherein the size of the annular short magnetic core 2 is 1230mm in outer diameter, 1030mm in inner diameter and 30mm in height, and the winding mold is made of wood;
s3, carrying out crystallization annealing treatment on the short magnetic core 2 in a vacuum environment, preserving heat for 180min at 465 ℃, then heating to 540 ℃ at the speed of 0.2 ℃/min, preserving heat for 180min, removing vacuum after cooling, and discharging; the dimensions of the ring-shaped magnetic core after cooling are approximately: the outer diameter is 1200mm, the inner diameter is 1000mm, and the height is 30 mm;
s4, uniformly coating a layer of silicon rubber on the bottom of the stainless steel protective box 1, sucking up the short magnetic core 2 by adopting an electromagnet with the shape consistent with the end face of the short magnetic core 2, and lightly putting the short magnetic core 2 on the silicon rubber layer in the stainless steel protective box 1; the end face of the electromagnet is made of electrician pure iron;
s5, uniformly coating a layer of silicon rubber on the other end face of the placed short magnetic core 2, sucking up the second short magnetic core 2 by adopting an electromagnet with the shape consistent with that of the end face of the short magnetic core 2, and moving and stacking the second short magnetic core 2 on the first short magnetic core 2;
s6, repeating the step S5 until the short magnetic core 2 in the stainless steel protective box 1 reaches the required height;
s7, uniformly coating a layer of silicon rubber on the end face of the short magnetic core 2 at the topmost layer, filling the silicon rubber in the gap between the short magnetic core 2 and the stainless steel protective box 1, and covering the cover plate 3 after the silicon rubber is dried completely to obtain the nanocrystalline alloy magnetic core product.
Example 4
The utility model provides an ultra-high super large nanocrystalline magnetic core, includes the magnetic core body, and the magnetic core body includes that the stainless steel protects box 1, apron 3 and 4 short magnetic cores 2, and the height of magnetic core body is 100mm, and the external diameter is 800mm, and internal diameter 600mm, weight are 123.4 kilograms, and the initial permeability of magnetic core body is greater than 8 ten thousand, and the net height ratio is greater than 88%. The short magnetic cores 2 are made of iron-based nanocrystalline soft magnetic alloy, and the plurality of short magnetic cores 2 are insulated from each other.
The nanocrystalline alloy magnetic core is formed by stacking 2 short magnetic cores 2 with the heights of 30mm and 20mm, the stainless steel protective box 1 is made of 304 stainless steel, the outer diameter of the stainless steel protective box is 815mm, the inner diameter of the stainless steel protective box is 585mm, the height of the stainless steel protective box is 107.5mm, and the wall thickness of the stainless steel protective box is 2.5 mm. The cover plate 3 is annular, the outer diameter is 816mm, the inner diameter is 584mm, the thickness is 2.5mm, and the material is epoxy resin.
A manufacturing method of an ultra-high and ultra-large iron-based nanocrystalline alloy magnetic core comprises the following steps:
s1, preparing an amorphous thin belt by a single-roller melt-spinning method, wherein the thickness of the amorphous thin belt is 30 +/-2 microns, and the width of the amorphous thin belt is 30mm or 20 mm;
s2, winding the amorphous thin coil into an annular short magnetic core 2, wherein the size of the annular short magnetic core 2 is 820mm in outer diameter, 620mm in inner diameter, 30mm and 20mm in height, and the winding mold is made of wood;
s3, carrying out crystallization annealing treatment on the short magnetic core 2 in a vacuum environment, preserving heat for 180min at 470 ℃, then heating to 540 ℃ at the speed of 0.3 ℃/min, preserving heat for 180min, removing vacuum after cooling, and discharging; the dimensions of the ring-shaped magnetic core after cooling are approximately: 800mm outside diameter, 600mm inside diameter, 30mm and 20mm height;
s4, uniformly coating a layer of silicon rubber on the bottom of the stainless steel protective box 1, sucking up the short magnetic core 2 by adopting an electromagnet with the shape consistent with the end face of the short magnetic core 2, and lightly putting the short magnetic core 2 on the silicon rubber layer in the stainless steel protective box 1; the end face of the electromagnet is made of electrician pure iron;
s5, uniformly coating a layer of silicon rubber on the other end face of the placed short magnetic core 2, sucking up the second short magnetic core 2 by adopting an electromagnet with the shape consistent with that of the end face of the short magnetic core 2, and moving and stacking the second short magnetic core 2 on the first short magnetic core 2;
s6, repeating the step S5 until the short magnetic core 2 in the stainless steel protective box 1 reaches the required height;
s7, uniformly coating a layer of silicon rubber on the end face of the short magnetic core 2 at the topmost layer, filling the silicon rubber in the gap between the short magnetic core 2 and the stainless steel protective box 1, and covering the cover plate 3 after the silicon rubber is dried completely to obtain the nanocrystalline alloy magnetic core product.
Example 5
The utility model provides an ultra-high super large nanocrystalline magnetic core, includes the magnetic core body, and the magnetic core body includes that the stainless steel protects box 1, apron 3 and 3 short magnetic cores 2, and the height of magnetic core body is 75mm, and the external diameter is 500mm, and internal diameter 400mm, weight are 29.8 kilograms. The short magnetic cores 2 are made of iron-based nanocrystalline soft magnetic alloy, the height of the short magnetic cores is 25mm, and the short magnetic cores 2 are insulated from each other.
The stainless steel protective box 1 is made of 304 stainless steel, and has the dimensions of 512mm external diameter, 388mm internal diameter, 82.5mm height and 2.5mm wall thickness. The cover plate 3 is annular, has an outer diameter of 513mm, an inner diameter of 387mm and a thickness of 2.5mm, and is made of epoxy resin.
A manufacturing method of an ultra-high and ultra-large iron-based nanocrystalline alloy magnetic core comprises the following steps:
s1, preparing an amorphous thin belt by a single-roller melt-spinning method, wherein the thickness of the amorphous thin belt is 30 +/-2 microns, and the width of the amorphous thin belt is 25 mm;
s2, winding the amorphous thin coil into an annular short magnetic core 2, wherein the size of the annular short magnetic core 2 is 512mm in outer diameter, 412mm in inner diameter and 30mm in height, and the winding mold is made of wood;
s3, carrying out crystallization annealing treatment on the short magnetic core 2 in a vacuum environment, preserving heat at 475 ℃ for 120min, raising the temperature to 550 ℃ at the speed of 0.3 ℃/min, preserving heat for 150min, cooling, removing vacuum, and discharging; the dimensions of the ring-shaped magnetic core after cooling are approximately: the outer diameter is 500mm, the inner diameter is 400mm, and the height is 30 mm;
s4, uniformly coating a layer of silicon rubber on the bottom of the stainless steel protective box 1, sucking up the short magnetic core 2 by adopting an electromagnet with the shape consistent with the end face of the short magnetic core 2, and lightly putting the short magnetic core 2 on the silicon rubber layer in the stainless steel protective box 1; the end face of the electromagnet is made of electrician pure iron;
s5, uniformly coating a layer of silicon rubber on the other end face of the placed short magnetic core 2, sucking up the second short magnetic core 2 by adopting an electromagnet with the shape consistent with that of the end face of the short magnetic core 2, and moving and stacking the second short magnetic core 2 on the first short magnetic core 2;
s6, repeating the step S5 until the short magnetic core 2 in the stainless steel protective box 1 reaches the required height;
s7, uniformly coating a layer of silicon rubber on the end face of the short magnetic core 2 at the topmost layer, filling the silicon rubber in the gap between the short magnetic core 2 and the stainless steel protective box 1, and covering the cover plate 3 after the silicon rubber is dried completely to obtain the nanocrystalline alloy magnetic core product.
Comparative example 1
The utility model provides an ultra-large nanocrystalline magnetic core, includes the magnetic core body, and the magnetic core body protects box 1 including short magnetic core 2, apron 3 and stainless steel, and the external diameter of magnetic core body is 815mm, and internal diameter 585mm, weight are 50 kilograms, highly are 37 mm.
The stainless steel protective box 1 is made of 304 stainless steel, and has the dimensions of 815mm of outer diameter, 585mm of inner diameter, 34.5mm of height and 2.5mm of wall thickness. The cover plate 3 is annular, the outer diameter is 815mm, the inner diameter is 585mm, the thickness is 2.5mm, and the material is epoxy resin.
A manufacturing method of an oversized iron-based nanocrystalline alloy magnetic core comprises the following steps:
s1, preparing an amorphous thin belt by a single-roller melt-spinning method, wherein the thickness of the amorphous thin belt is 30 +/-2 microns, and the width of the amorphous thin belt is 30 mm;
s2, winding the amorphous thin coil into an annular short magnetic core 2, wherein the size of the annular short magnetic core 2 is 815mm in outer diameter, 615mm in inner diameter and 30mm in height, and the winding mold is made of wood;
s3, carrying out crystallization annealing treatment on the short magnetic core 2 in a vacuum environment, preserving heat for 180min at 470 ℃, heating to 540 ℃ at the speed of 0.3 ℃/min, preserving heat for 180min, removing vacuum after cooling, and discharging;
s4, uniformly coating a layer of silicon rubber on the end face of the short magnetic core 2, filling the silicon rubber in the gap between the short magnetic core 2 and the stainless steel protective box 1, and covering the cover plate 3 after the rubber is dried completely to obtain the nanocrystalline alloy magnetic core product.
Comparative example 2
A conventional nanocrystalline magnetic core comprises a magnetic core body, wherein the magnetic core body comprises a DMC protective box and a short magnetic core 2, the height of the magnetic core body is 34mm, the outer diameter is 81mm, the inner diameter is 43mm, and the weight is 0.592 kg. The size of the protective box is 81mm of external diameter, 43mm of internal diameter and 34mm of height, and the material is DMC resin
A method for manufacturing a conventional iron-based nanocrystalline alloy magnetic core comprises the following steps:
s1, preparing an amorphous thin belt by a single-roller melt-spinning method, wherein the thickness of the amorphous thin belt is 30 +/-2 microns, the width of the amorphous thin belt is 30mm, and a mould for preparing the amorphous thin belt is made of wood;
s2, winding the amorphous thin coil into an annular short magnetic core 2, wherein the size of the annular short magnetic core 2 is 78mm in outer diameter, 48mm in inner diameter and 30mm in height, and the winding mold is made of wood;
s3, carrying out crystallization annealing treatment on the short magnetic core 2 in a vacuum environment, preserving heat at 480 ℃ for 120min, raising the temperature to 550 ℃ at the speed of 0.1 ℃/min, preserving heat for 150min, cooling, removing vacuum, and discharging; the dimensions of the annular short magnetic core 2 after cooling are approximately: the outer diameter is 77mm, the inner diameter is 47mm, and the height is 30 mm;
s4, uniformly coating a layer of silicon rubber on the end face of the short magnetic core 2, loading the short magnetic core into a DMC (metal matrix) protective box, and finishing the manufacture of the magnetic core after the glue is dried completely to obtain the common iron-based nanocrystalline alloy magnetic core.
The magnetic cores of example 1, example 2, example 3, example 4, example 5, comparative example 1 and comparative example 2 were tested for their performance, and the results are shown in the following table:
as can be seen from the data in the table, the net height ratio of the ultrahigh and ultra-large magnetic core can reach more than 88 percent, and is higher than that of the shorter ultra-large magnetic core in the comparative example 1 and is equivalent to that of the small and medium magnetic core in the comparative example 2; the initial permeability of the ultrahigh and ultra-large magnetic core can reach more than 8 ten thousand, which is slightly lower than the numerical value of the shorter and ultra-large magnetic core in the comparative example 1, the initial permeability of the small magnetic core in the comparative example 2 can reach about 28 ten thousand, but for the ultra-large magnetic core, the initial permeability is obviously reduced; the ultrahigh and ultra-large magnetic core has higher initial permeability, even if the input-output turn ratio is 1: 1, when the input current I is small, a large output electromotive force V can be obtained, and the requirement of a high-voltage transformer with a small transformation ratio can be met.
The foregoing illustrates and describes the principles, general features, and advantages of the present invention. It should be understood by those skilled in the art that the above embodiments do not limit the present invention in any way, and all technical solutions obtained by using equivalent alternatives or equivalent variations fall within the scope of the present invention.
Claims (4)
1. A nanocrystalline magnetic core comprises a magnetic core body and is characterized in that the magnetic core body comprises a stainless steel protective box, a cover plate and a plurality of short magnetic cores, the height of the magnetic core body is 68-162 mm, the outer diameter is 512-1220 mm, the inner diameter is 388-980 mm, the weight is 38-178 kg, the initial magnetic conductivity of the magnetic core body is more than 8 ten thousand, the net height ratio is more than 88%, the short magnetic cores are made of iron-based nanocrystalline soft magnetic alloys, the height is 20-30mm, and the short magnetic cores are mutually insulated;
the manufacturing method of the magnetic core body comprises the following steps:
s1, preparing an amorphous thin belt by adopting a single-roller melt-spun method;
s2, winding the amorphous thin coil into an annular short magnetic core;
s3, carrying out crystallization annealing treatment on the short magnetic core in a vacuum environment, cooling, removing vacuum, and discharging;
s4, uniformly coating a layer of silicon rubber on the bottom of the stainless steel protective box, sucking up the short magnetic core by adopting an electromagnet with the shape consistent with the end face of the short magnetic core, and lightly putting the short magnetic core on the silicon rubber layer in the stainless steel protective box;
s5, uniformly coating a layer of silicon rubber on the other end face of the placed short magnetic core, sucking up the second short magnetic core by adopting an electromagnet with the shape consistent with that of the end face of the short magnetic core, and moving and stacking the second short magnetic core on the first short magnetic core;
s6, repeating the step S5 until the short magnetic core in the stainless steel protective box reaches the required height;
s7, uniformly coating a layer of silicon rubber on the end face of the short magnetic core at the topmost layer, filling the silicon rubber in a gap between the short magnetic core and the stainless steel protective box, and covering a cover plate after the silicon rubber is dried completely to obtain a nanocrystalline alloy magnetic core product;
in step S3, the conditions of the crystallization annealing process are as follows: preserving heat for 120-180 min at 465-475 ℃, then heating to 540-550 ℃, preserving heat for 150-180 min, wherein the heating rate is less than 0.3 ℃/min during the heating to 540-550 ℃.
2. The nanocrystalline magnetic core according to claim 1, wherein in step S1, the amorphous ribbon has a thickness of 30 ± 2 μm and a width of 20 to 30 mm.
3. The magnetic core of claim 1, wherein in step S2, the winding mold is made of wood.
4. The nanocrystalline core according to claim 1, wherein in steps S4 and S5, the electromagnet end faces are made of electrical pure iron.
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