CN113436852B - Three-dimensional transformer iron core and transformer of rolling up - Google Patents
Three-dimensional transformer iron core and transformer of rolling up Download PDFInfo
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- CN113436852B CN113436852B CN202110558928.1A CN202110558928A CN113436852B CN 113436852 B CN113436852 B CN 113436852B CN 202110558928 A CN202110558928 A CN 202110558928A CN 113436852 B CN113436852 B CN 113436852B
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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
- H01F27/00—Details of transformers or inductances, in general
- H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
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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)
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Abstract
The invention belongs to the technical field of transformers, and particularly relates to a three-dimensional wound transformer core. The utility model provides a three-dimensional transformer core of rolling up, includes three single frame iron core that the structure is the same, single frame iron core includes bilateral symmetry's iron leg and longitudinal symmetry's yoke, and bilateral symmetry's iron leg and longitudinal symmetry's yoke enclose into the rectangle window jointly, single frame iron core is formed by the strip coiling, and adjacent two-layer strip dislocation is convoluteed, and the strip coiling is become single frame iron core both sides limit and is the cambered surface, single frame iron core's iron leg inboard is the inclined plane, and every single frame iron core is connected through the iron leg with two other single frame iron cores and is made up into three-phase three-dimensional iron core structure of rolling up, and the core leg inclined plane of two adjacent single frame iron cores is laminated. According to the three-dimensional wound transformer core provided by the invention, under the condition of the same weight of core, the cross section area of the yoke part is larger than the magnetic density of the yoke part of the three-dimensional wound core in the traditional scheme, so that the integral iron loss is smaller.
Description
Technical Field
The invention belongs to the technical field of transformers, and particularly relates to a three-dimensional winding transformer core and a transformer.
Background
With the continuous improvement of the technical level, the amorphous alloy transformer is widely applied in the field of power distribution, and the technology of the amorphous alloy three-dimensional wound core transformer is rapidly developed. The three-dimensional wound core transformer is an efficient energy-saving transformer developed in recent years, the processing technology of the wound core is more suitable for using a magnetic steel strip with thin specification, high magnetic induction and ultralow loss, favorable conditions are provided for reducing the no-load loss of the transformer and improving the energy efficiency of the transformer, and the energy efficiency of the transformer can reach 1-grade and 2-grade energy efficiencies of the latest national power transformer energy efficiency limit value and energy efficiency grade 20052-2020 standard.
The amorphous stereoscopic wound core is mainly formed by sequentially and continuously winding a plurality of trapezoidal material belts with different sizes, three rectangular iron core frames 1 (see figure 1) with approximate semicircular sections and completely identical geometric sizes are obtained, every two same sides of the three iron core frames 1 are spliced, three core columns of the iron core are arranged in an equilateral triangle three-dimensional mode after splicing, the cross sections of the iron core columns are close to a circle, the three iron core magnetic circuits are consistent in length, and the lengths of iron yokes are all shortest, so that the iron core is light in weight and small in no-load loss. The production process from the iron core to the coil is greatly different from the traditional laminated iron core, special manufacturing equipment is needed, and the current automation degree is obviously improved.
The single-frame iron core of the three-dimensional winding transformer on the market at present needs to be sequentially and continuously wound by trapezoidal materials with different sizes, and the trapezoidal material strips with different sizes need to be obtained by firstly performing oblique shearing and then being wound by special winding equipment and a die. The process is complex, and special nonstandard oblique shearing equipment needs to be designed. The winding process has high requirement on control precision, and the winding equipment is complex, thereby invisibly improving the manufacturing cost of the three-dimensional winding transformer. Therefore, a new solution is needed to be provided, which can realize the transformer scheme of the three-dimensional coil, but the requirements on the control precision and the equipment in the process are not high, and the production cost of the three-dimensional coil transformer can be reduced as a whole.
Disclosure of Invention
In order to solve the problems in the background art, the invention provides a three-dimensional winding transformer core and a transformer, and the three-dimensional winding transformer core is lower in manufacturing cost; under the condition of the same weight, the cross section area of the yoke part of the three-dimensional wound transformer core is larger than the yoke part of the three-dimensional wound core in the traditional scheme, so that the integral iron loss of the three-dimensional wound core is smaller.
Has the advantages of low cost and simple process.
A three-dimensional winding transformer core is characterized in that,
comprises three single-frame iron cores with the same structure, wherein each single-frame iron core comprises iron core columns which are symmetrical left and right and iron yokes which are symmetrical up and down, the iron core columns which are symmetrical left and right and the iron yokes which are symmetrical up and down enclose a rectangular window,
the single-frame iron core is formed by winding strips, two adjacent layers of strips are wound in a staggered manner, the strips are wound to form cambered surfaces at two side edges of the single-frame iron core, the inner side of an iron core column of the single-frame iron core is an inclined surface,
each single-frame iron core is connected with the other two single-frame iron cores through iron core columns to form a three-phase three-dimensional wound iron core structure, and core column inclined planes of the two adjacent single-frame iron cores are attached.
Further, the single frame core is formed by winding strips having the same width.
Further, the strip is an amorphous alloy strip.
Further, the single frame core needs to be subjected to a varnish treatment.
Furthermore, the inclined plane of the inner side of the core limb of the single frame iron core is processed by adopting a linear cutting mode.
The transformer is characterized by comprising any one of the three-dimensional winding transformer cores.
The technical scheme for solving the problems is as follows: the manufacturing process of the three-dimensional wound transformer core is characterized by comprising the following steps of:
s1: installing an inner die for winding the iron core on the iron core winding machine;
s2: introducing a suitable width of strip (depending on the specific core design size);
s3: the winding machine automatically winds according to the designed size of the iron core;
s4: after the single-frame iron core is wound to the shape size meeting the design requirement, cutting off the strip, and hoisting the strip together with the winding inner die and the iron core away from the winding machine;
s5: the annular iron core is manufactured into a rectangular shape and is fixed and molded by an outer mold, and then the manufacturing of the single-frame iron core is completed;
s6: repeating the operation S2-S5 to finish another two single-frame iron cores;
s7: and (4) selecting a special annealing furnace, and annealing the iron core with the mold. Its advantages are single frame, single heat treatment, simple operation and large-scale production.
S8: the single-frame iron core is subjected to paint dipping by selecting a proper paint dipping material, and the single-frame iron core has the advantages that the structural strength of the single-frame iron core is realized, the wire cutting is facilitated, and the interlayer gap and the rusting of a strip material are avoided. And the mechanical damage probability of the iron core in the transportation and transformer assembly processes is greatly reduced, and the product quality is ensured.
S9: according to the design requirement of the iron core structure, the core column of the iron core is subjected to bevel cutting, so that the three-phase iron core splicing requirement is met. Compared with the traditional three-dimensional iron core, the process mode has the advantages that the strip is obliquely cut, the production efficiency is higher, the iron core size control precision is better, and the operation is simple.
S10: three single-frame iron cores are combined into a three-phase three-dimensional iron core rolling structure by adopting a special iron core combination device.
Further, in step S2, the width of the strip is fixed.
Furthermore, in step S3, the tension of the strip material is controlled and the pressing force of the strip material wound on the iron core is controlled during winding, so as to achieve the requirement of tightly and smoothly winding the strip material.
Further, in the step S2, the ribbon is an amorphous ribbon.
Further, in the step S4, two adjacent layers of strips are wound in a staggered manner, and the two sides of the strip wound into the single-frame iron core are cambered surfaces.
The invention has the advantages that:
the manufacturing method of the three-dimensional wound transformer iron core adopts the strips with the same width to wind, and the strip is integrally cut after the core column of the iron core is wound into the cambered surface, so that compared with the traditional three-dimensional iron core, the production efficiency is higher, the iron core size control precision is better, and the operation is simple; compared with the traditional three-dimensional roll process, the novel process method for winding the amorphous three-dimensional roll iron core in the wire-cutting mode is simple, reduces the process flow and the equipment complexity, further reduces the production cost, and makes a contribution to national energy conservation and emission reduction and environmental pollution reduction.
The three-dimensional wound iron core of the transformer has the advantages that the maximum power output by the iron core with the same weight is equivalent to that of the three-dimensional wound iron core in the traditional scheme; the sectional area of the core column of the iron core with the same weight is smaller than that of the three-dimensional iron wire coil in the traditional scheme, and the copper consumption is smaller under the same current density; under the same condition of using the copper quantity, the output power is higher; the sectional area of the yoke part of the iron core with the same weight is larger than the magnetic density of the yoke part of the three-dimensional wound iron core in the traditional scheme, so that the iron loss of the whole iron core is smaller.
Drawings
FIG. 1 is a prior art conventional solid-coiled transformer core;
FIG. 2 is a schematic workflow of the present invention;
FIG. 3 is a schematic view of a single-frame core structure fabricated by the method of the present invention;
FIG. 4 is another directional view of FIG. 3;
FIG. 5 is a schematic diagram of a three-dimensional wound transformer core made by the method of the present invention;
fig. 6 is a conventional three-dimensional wound core magnetic circuit;
FIG. 7 is a software simulation of the cross-sectional areas of a conventional three-dimensional wound transformer core and a three-dimensional wound transformer core according to the present invention;
FIG. 8 is a diagram of the area of a window of a conventional three-dimensional wound transformer core and a three-dimensional wound transformer core according to the present invention;
FIG. 9 is a simulated view of magnetic flux density of a conventional three-dimensionally wound transformer core and a three-dimensionally wound transformer core according to the present invention;
fig. 10 is a current density simulation diagram of a conventional stereoscopic transformer core and a stereoscopic transformer core according to the present invention.
Wherein, 1-single frame iron core, 2-iron yoke, 3-iron core column, 4, cambered surface, 5 and inclined surface.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings of the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention. Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention.
Referring to fig. 2, a method for manufacturing a three-dimensional transformer core includes two parts: firstly, manufacturing a single-frame iron core 1, and then combining the single-frame iron core 1 into a three-phase three-dimensional wound iron core.
Two parts are required for manufacturing the single-frame iron core 1: 1. selecting a proper strip with a conventional width, and winding the strip on a die with a certain outline dimension through an arc surface 4 to form a basic shape of the iron core; 2. and performing linear cutting on the wound strip to finish the final molding of the single-frame iron core 1.
The manufacturing method of the single-frame iron core 1 specifically comprises the following steps:
s1: installing an inner die for winding the iron core on the iron core winding machine;
s2: introducing a suitable width of strip (depending on the particular core design size); by selecting the appropriate bandwidth, control of winding positioning and shape and interior window mold design are important guarantees for this step;
s3: the winding machine automatically winds according to the designed size of the iron core;
s4: after the single-frame iron core 1 is wound until the external dimension meets the design requirement, cutting off the strip, and lifting away from the winding machine together with the winding inner die and the iron core;
s5: the annular iron core is made into a rectangular shape to form a core column 3 which is symmetrical left and right and an iron yoke 2 which is symmetrical up and down, and the core column and the iron yoke are fixed and formed by an outer die, thus completing the manufacture of a single-frame iron core 1;
s6: repeating the operation S2 to S5 to finish the other two single-frame iron cores 1;
s7: the special annealing furnace for the alloy iron core is selected, and the iron core is annealed with the die. Its advantages are single frame, single heat treatment, simple operation and large-scale production.
S8: the single-frame iron core 1 is subjected to paint dipping by selecting a proper paint dipping material, and the single-frame iron core 1 has the advantages that the structural strength of the single-frame iron core 1 is realized, the linear cutting can be facilitated, and the interlayer gap and the rusting of the strip are not worried. And the mechanical damage probability of the iron core in the transportation and transformer assembly processes is greatly reduced, and the product quality is ensured.
S9: and according to the structural design requirement of the iron core, cutting an inclined plane 5 on each core column of the single-frame iron core 1 to meet the splicing requirement of the three-phase iron core. Compared with the traditional three-dimensional iron core, the process mode has the advantages that the strip is obliquely sheared, the production efficiency is higher, the iron core size control precision is better, and the operation is simple.
In a preferred embodiment of the present invention, in step S2, the width of the strip is fixed.
In a preferred embodiment of the present invention, in step S3, the tension of the strip material is controlled and the pressing force of the strip material wound around the iron core is controlled to achieve the requirement of tightly and smoothly winding the strip material.
In a preferred embodiment of the present invention, in the step S2, the strip is an amorphous strip.
In the step S4, two layers of strip materials are wound in a staggered manner, and the two sides of the strip materials wound into the single frame iron core 1 are arc surfaces 4, as shown in fig. 3 and 4.
Compared with the traditional three-dimensional winding process, the invention adopts the strip with the same width, thereby saving the process time and cost of oblique shearing of the strip and simultaneously reducing the technical difficulty of the winding machine.
And finally, combining the single-frame iron core 1 into a three-phase three-dimensional wound iron core, which specifically comprises the following steps:
the iron core columns 3 of two adjacent single-frame iron cores 1 are cut into the inclined planes 5 for lamination, and a special iron core combination device is adopted to combine the three single-frame iron cores 1 into a three-phase three-dimensional rolled iron core structure.
Three-phase three-dimensional coil iron core structure performance test
The performance detection of the finished amorphous three-dimensional wound core manufactured by the method is mainly to perform a B value test on three different sections, including a qualitative test and a quantitative test. The method comprises the steps of testing whether the curve of the B is smooth, whether distortion points exist or not and whether the three phases are symmetrical or not. And a quantitative test, i.e. whether the value of B at a given voltage meets the design requirements.
The novel process method for winding the amorphous three-dimensional wound core in the wire-cutting mode is simpler than the traditional three-dimensional winding process, reduces the process flow and the equipment complexity, further reduces the production cost, and contributes to energy conservation and emission reduction of the country and reduction of environmental pollution.
Referring to fig. 5, the three-dimensional wound transformer core is manufactured by the method and comprises three single-frame cores 1 with the same structure, each single-frame core 1 comprises core legs 3 which are bilaterally symmetrical and yokes 2 which are bilaterally symmetrical, the core legs 3 which are bilaterally symmetrical and the yokes 2 which are bilaterally symmetrical enclose a rectangular window, each single-frame core 1 is formed by winding strips, two adjacent layers of the strips are wound in a staggered mode, two side edges of each single-frame core 1 after the strips are wound are cambered surfaces 4, and the inner sides of the core legs 3 of each single-frame core 1 are inclined surfaces 5. Each single-frame iron core 1 is connected with the other two single-frame iron cores 1 through iron core columns 3 to form a three-phase three-dimensional iron core rolling structure, and the inclined planes of the core columns of the two adjacent single-frame iron cores 1 are attached.
In a preferred embodiment of the present invention, the single-frame core 1 is formed by winding a strip having the same width.
In a preferred embodiment of the present invention, the ribbon is an amorphous alloy ribbon.
As a preferred embodiment of the present invention, the above-described single-frame iron core 1 needs to be subjected to a painting process.
In a preferred embodiment of the present invention, the inclined surface of the inner side of the core leg 3 of the single-frame iron core 1 is formed by wire cutting.
A transformer comprises the three-dimensional winding transformer core. Because the transformer comprises the three-dimensional winding transformer core, the transformer has all the structures and effects of the three-dimensional winding transformer core, and the details are not repeated here.
Traditional three-dimensional wound core magnetic circuit: the conventional three-phase three-dimensional wound core is composed of three planar wound cores having independent magnetic circuits, and the core leg 3 of each phase winding is composed of two wound cores connected in parallel, as shown in fig. 6. The cross section of a yoke part of a traditional three-dimensional coil is equal to the cross section of a core part of the traditional three-dimensional coil, but a larger magnetic flux flows in, the magnetic flux does not contribute to an excitation voltage, but can cause a larger iron loss, and the calculation method comprises the following steps:
obviously, when calculating the loss and the excitation current in the iron core, the iron core magnetic density Bm (AB) should be used instead of calculating the magnetic density Bm. Otherwise, the calculated no-load loss and exciting current are obviously smaller than the actual values.
The scheme of the iron core of the three-dimensional winding transformer provided by the invention can perform linear cutting with a certain degree of freedom, so that the relative section ratio of the yoke part is larger.
Taking a conventional 400KVA capacity three-dimensional winding amorphous transformer core and the three-dimensional winding amorphous transformer core provided by the invention as examples, referring to FIGS. 7-10, the parameters are calculated, and the parameters are compared as shown in Table 1:
TABLE 1
The test result of the given pure resistance load of the traditional three-dimensional amorphous-wound transformer core is shown in table 2. The test result of the given pure resistance load of the three-dimensional amorphous transformer core is shown in the table 3.
TABLE 2
| Given load resistance | Input power | Output power | Copper loss | Iron loss | Efficiency of |
| 0.38 | 398307.824 | 387867.803 | 5702 | 256 | 0.959437528 |
| 0.5R | 306556.26 | 297050.6748 | 3450 | 211 | 0.95755689 |
TABLE 3
| Given load resistance | Input power | Output power | Copper loss | Iron loss | Efficiency of |
| 0.38 | 398407.835 | 387868.9 | 5695 | 242 | 0.959437528 |
| 0.5R | 306756.45 | 297050.8 | 3436 | 206 | 0.95755689 |
The three-dimensional wound amorphous transformer core provided by the invention has equivalent output power and efficiency with the traditional three-dimensional wound amorphous transformer core under the same given conditions, and the copper loss and the iron loss of the wire-cutting three-dimensional wound are slightly less. The three-dimensional coil adopting the two schemes has the advantages that under the condition of the same weight, the performance of the three-dimensional coil adopting the wire cutting mode and the three-dimensional coil adopting the traditional winding mode is almost the same, but the section of a core column adopting the wire cutting mode is smaller, so that the copper consumption of a winding can be effectively reduced, and the overall cost is reduced. In addition, the external wire cutting mode has simple process and high forming precision. The finished product saves materials, reduces the production cost, and makes contributions to national energy conservation, emission reduction and environmental pollution reduction.
The above description is only an embodiment of the present invention, and not intended to limit the scope of the present invention, and all equivalent structures or equivalent flow transformations that are made by using the contents of the present specification and the drawings, or directly or indirectly applied to other related system fields, are included in the scope of the present invention.
Claims (4)
1. A three-dimensional transformer core that rolls up which characterized in that:
comprises three single-frame iron cores with the same structure, wherein each single-frame iron core comprises iron core columns which are symmetrical left and right and iron yokes which are symmetrical up and down, the iron core columns which are symmetrical left and right and the iron yokes which are symmetrical up and down enclose a rectangular window,
the single-frame iron core is formed by winding strips with the same width, two adjacent layers of strips are wound in a staggered mode, the strips are wound to form arc surfaces on two side edges of the single-frame iron core, the inner side of an iron core column of the single-frame iron core is an inclined surface, and the inclined surface on the inner side of the iron core column of the single-frame iron core is processed in a linear cutting mode;
each single-frame iron core is connected with the other two single-frame iron cores through iron core columns to form a three-phase three-dimensional iron core rolling structure, and the core column inclined planes of the two adjacent single-frame iron cores are attached.
2. A three-dimensional wound transformer core as claimed in claim 1, wherein:
the strip is an amorphous alloy strip.
3. A three-dimensional wound transformer core as claimed in claim 1, wherein:
the single-frame iron core needs to be subjected to paint dipping treatment.
4. A transformer, characterized by:
comprising a solid-wound transformer core as claimed in any one of the claims 1-3.
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| CN201364795Y (en) * | 2008-09-02 | 2009-12-16 | 谷侃 | Transformer iron core with laminated sheet type three-phase spatial structure |
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| US4953286A (en) * | 1988-12-12 | 1990-09-04 | Cooper Industries, Inc. | Method of making a transformer core |
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| CN201364795Y (en) * | 2008-09-02 | 2009-12-16 | 谷侃 | Transformer iron core with laminated sheet type three-phase spatial structure |
| CN102364642A (en) * | 2010-06-08 | 2012-02-29 | Abb技术有限公司 | Method for manufacture of triangular transformer cores made of amorphous metal |
| CN104221105A (en) * | 2012-01-17 | 2014-12-17 | U.T.T.独特变压器科技股份有限公司 | Three-phase magnetic cores for magnetic induction devices and methods for manufacturing them |
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