CN116504525B - Method for preparing iron core by adopting ultrathin oriented silicon steel, iron core and application - Google Patents
Method for preparing iron core by adopting ultrathin oriented silicon steel, iron core and application Download PDFInfo
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Classifications
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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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- 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
-
- 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
-
- 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
- H01F41/005—Impregnating or encapsulating
-
- 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
-
- 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
- H01F2027/348—Preventing eddy currents
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
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Abstract
A method for preparing an iron core by adopting ultrathin oriented silicon steel and an iron core and application thereof belong to the technical field of iron cores for transformers or reactors, and overcome the defects of low working magnetic density, large volume and heavy weight of the transformer caused by high iron loss of the iron core under the conditions of medium and high frequency and high magnetic flux density in the prior art. The method for preparing the iron core by adopting the ultrathin oriented silicon steel comprises the following steps of: step 1, selecting ultrathin oriented silicon steel with the thickness less than or equal to 0.10mm as a raw material; step 2, cutting the ultrathin oriented silicon steel into strips, and winding the strips into iron cores; step 3, clamping and fixing the iron core; step 4, placing the fixed iron core into a vacuum tube type heat treatment furnace, and carrying out graded pulse annealing treatment on the iron core in a pulse current mode with unchanged direction, wherein the pulse current intensity is increased along with the increase of the annealing temperature; and 5, dipping and drying the iron core subjected to the graded pulse annealing. The preparation method has low energy consumption and low loss of the prepared iron core at high frequency.
Description
Technical Field
The invention belongs to the technical field of iron cores for transformers or reactors, and particularly relates to a method for preparing an iron core by adopting ultrathin oriented silicon steel, the iron core and application.
Background
The iron core is a core component of devices such as a transformer, a reactor and the like, and the performance improvement of the iron core has important significance for realizing low-loss current conversion of the transformer and high-reliability reactive compensation of the saturated reactor.
Currently, the common transformer or reactor iron core mainly comprises an oriented silicon steel iron core and an amorphous alloy iron core. The oriented silicon steel core is formed by stacking or winding a plurality of oriented silicon steel sheets with the thickness of 0.18-0.35 mm, and has the advantages of excellent electromagnetic performance, low cost, small influence of mechanical stress, low noise and the like. Literature (Huang P., mao C.X., wang D., wang L.B., duan Y.P., qia J., xu G, cai H.H. Optimal Design and Implementation of High-Voltage High-Power Silicon Steel Core Medium Frequency Transformer) reports a 1kHz/35kV transformer based on a 0.18mm oriented silicon steel core, which has the advantages of High saturation magnetic flux density, low cost, small noise, easy processing, and the like, and has an operating efficiency of 99% or more, but the iron loss at a frequency of 1kHz increases approximately parabolic with the increase of the magnetic flux density, so that the operating magnetic density of the oriented silicon steel core transformer is low, and the volume and weight of the transformer are large in order to reduce the operating loss.
Disclosure of Invention
Therefore, the invention aims to overcome the defects of low working magnetic density, large volume and heavy weight of a transformer caused by high iron loss of an iron core under the conditions of medium and high frequency and high magnetic flux density in the prior art, thereby providing a method for preparing the iron core by adopting ultrathin oriented silicon steel, the iron core and application thereof.
For this purpose, the invention provides the following technical scheme.
A method for preparing an iron core by adopting ultrathin oriented silicon steel comprises the following steps:
step 1, selecting ultrathin oriented silicon steel with the thickness less than or equal to 0.10mm as a raw material;
step 2, cutting the ultrathin oriented silicon steel into strips according to the width requirement of the iron core, and winding the strips into the iron core;
step 3, clamping and fixing the iron core;
step 4, placing the fixed iron core into a vacuum tube type heat treatment furnace, and carrying out graded pulse annealing treatment on the iron core in a pulse current mode with unchanged direction, wherein the pulse current intensity is increased along with the increase of the annealing temperature;
and 5, dipping and drying the iron core subjected to the graded pulse annealing.
Further, in the step 4, the pulse current pulse frequency of the graded pulse annealing is 50-1000 Hz, and the pulse current intensity is 5-200A.
Further, the graded pulse annealing includes:
heating the furnace temperature from room temperature to 400-450 ℃, preserving heat for 0.5-1 hour, and simultaneously applying 5-50A pulse current;
continuously heating the furnace temperature to 600-650 ℃, preserving heat for 1-2 hours, and simultaneously applying 50-80A pulse current;
continuously heating the furnace temperature to 750-800 ℃, preserving heat for 1-2 hours, and simultaneously applying 80-200A pulse current;
and (5) cooling.
Further, the cooling includes:
cooling the furnace temperature to 400-500 ℃ under the condition of applying 50-200A pulse current;
and then cooling the furnace temperature to room temperature under the condition of applying 5-50A pulse current.
Further, at least one of the following conditions is satisfied:
(1) Heating the furnace temperature to 400-450 ℃ at a heating rate of 5-10 ℃/min;
(2) Heating the furnace temperature to 600-650 ℃ at a heating rate of 3-5 ℃/min;
(3) Heating the furnace temperature to 750-800 ℃ at a heating rate of 1-2 ℃/min;
(4) Reducing the furnace temperature to 400-500 ℃ at a cooling rate of 0.5-1 ℃/min;
(5) And cooling the furnace temperature to room temperature at a cooling rate of 1-3 ℃/min.
Further, the step 5 includes: placing the iron core into an impregnation tank, introducing an impregnating agent into the impregnation tank to submerge the iron core, and impregnating under the action of pressure; the impregnant is extracted, and air flow is introduced to dry the iron core.
Further, the pressure is 0.5-2 MPa, and the soaking time is 1-3 hours.
Further, the step 5 further comprises shaping treatment, abrasive wheel cutting and end face grinding and polishing.
Furthermore, the surface of the ultrathin oriented silicon steel is coated with an insulating coating, and the thickness of the insulating coating is 1-2 mu m.
A core made according to the above method.
The iron core manufactured by the method is applied to a transformer or a reactor.
The technical scheme of the invention has the following advantages:
1. the invention provides a method for preparing an iron core by adopting ultrathin oriented silicon steel, which comprises the following steps: step 1, selecting ultrathin oriented silicon steel with the thickness less than or equal to 0.10mm as a raw material; step 2, cutting the ultrathin oriented silicon steel into strips according to the width requirement of the iron core, and winding the strips into the iron core; step 3, clamping and fixing the iron core; step 4, placing the fixed iron core into a vacuum tube type heat treatment furnace, and carrying out graded pulse annealing treatment on the iron core in a pulse current mode with unchanged direction, wherein the pulse current intensity is increased along with the increase of the annealing temperature; and 5, carrying out dipping and drying treatment on the iron core after annealing the graded pulse.
According to the invention, the ultrathin oriented silicon steel with the thickness less than or equal to 0.10mm is selected as the raw material, and compared with the oriented silicon steel with the thickness of 0.18-0.35 mm, the ultrathin oriented silicon steel has small eddy current loss at a medium-high frequency of 600-1000 Hz due to the remarkably reduced thickness, so that the overall loss is lower.
The invention adopts graded pulse annealing, the current increases with the temperature rise, the pulse direction is unchanged, the energizing mode can ensure that the magnetic domain orientation of the iron core does not change obviously with the temperature rise, the magnetic performance is improved, the consumption of electric energy and the influence of the magnetic field acting force on the internal stress of the iron core are obviously reduced, and the energy-saving effect is strong.
2. In the method for preparing the iron core by adopting the ultrathin oriented silicon steel, the graded pulse annealing comprises the following steps: heating the furnace temperature from room temperature to 400-450 ℃, preserving heat for 0.5-1 hour, and simultaneously applying 5-50A pulse current; continuously heating the furnace temperature to 600-650 ℃, preserving heat for 1-2 hours, and simultaneously applying 50-80A pulse current; continuously heating the furnace temperature to 750-800 ℃, preserving heat for 1-2 hours, and simultaneously applying 80-200A pulse current.
The temperature of each part of the iron core is kept consistent in the temperature rising stage in the graded temperature rising process, so that the thermal stress of the iron core in the temperature rising process is reduced.
The temperature is kept between 750 and 800 ℃ for 1 to 2 hours, under the annealing temperature and the heat-preserving time, each part of the iron core is kept heated uniformly, the annealing temperature requirement can be met, lattice defects and internal stress generated in the shearing and winding processes can be eliminated, a more stable structure is formed, and meanwhile, energy consumption, cost increase and abnormal growth of iron core grains caused by overhigh temperature can be avoided; when the insulating coating is arranged on the surface of the ultrathin oriented silicon steel, the insulating coating on the surface of the ultrathin oriented silicon steel can be prevented from being damaged by high temperature.
The graded pulse current ensures the magnetic domain orientation of the iron core, reduces the energy consumption and is more beneficial to industrial production; meanwhile, the situation that the magnetic property of the iron core is poor because the internal stress of the iron core cannot be completely eliminated due to the magnetic field generated by overlarge current intensity is avoided.
3. In the method for preparing the iron core by adopting the ultrathin oriented silicon steel provided by the invention, the cooling comprises the following steps: cooling the furnace temperature to 400-500 ℃ under the condition of applying 50-200A pulse current; and then cooling the furnace temperature to room temperature under the condition of applying 5-50A pulse current.
The cooling process not only can lead the iron core not to generate residual thermal stress to deform, but also can greatly improve the yield strength of the iron core at 400-500 ℃, and the stress generated by the iron core due to the rapid cooling rate is lower than the yield strength, so that the permanent deformation cannot be generated to influence the magnetic performance.
4. In the method for preparing the iron core by adopting the ultrathin oriented silicon steel provided by the invention, the step 5 comprises the following steps: placing the iron core into an impregnation tank, introducing an impregnating agent into the impregnation tank to submerge the iron core, and impregnating under the action of pressure; the impregnant is extracted, and air flow is introduced to dry the iron core.
In the present invention, the impregnating agent is extracted after impregnation, and the air flow is introduced to dry the core. The conventional high-pressure impregnation and drying and curing steps are combined into a whole, and drying treatment can be directly realized in a paint dipping tank (the conventional drying treatment requires taking out the iron core in the dipping tank, firstly, carrying out paint emptying for a period of time, and then, drying and curing in a drying box), so that the processing flow is saved, and the efficiency is improved.
Detailed Description
The following examples are provided for a better understanding of the present invention and are not limited to the preferred embodiments described herein, but are not intended to limit the scope of the invention, any product which is the same or similar to the present invention, whether in light of the present teachings or in combination with other prior art features, falls within the scope of the present invention.
The specific experimental procedures or conditions are not noted in the examples and may be followed by the operations or conditions of conventional experimental procedures described in the literature in this field. The reagents or apparatus used were conventional reagent products commercially available without the manufacturer's knowledge.
The preparation method of the oriented silicon steel iron core comprises the following steps:
(1) Selecting materials: selecting ultrathin oriented silicon steel with the thickness less than or equal to 0.10mm and with the surface coated with an insulating coating with the thickness of 1-2 mu m as a raw material;
(2) Cutting and rolling: the method comprises the steps of placing raw materials into iron core winding equipment, wherein the winding equipment comprises an uncoiler, a buffer pit, a feeding roller, a shearing machine, a punching machine, a servo motor, a winding machine head and a pressing device, firstly longitudinally shearing the raw materials into strips with the width of 30-80 mm, and then winding the strips into an annular iron core according to the shape of a die. In order to ensure that the strip is tightly molded and rolled according to the shape of the mold and reduce the loss caused by gaps, a pressing device is required to be controlled in the rolling process so that the stacking coefficient is not less than 0.95.
(3) And (3) die pressing binding, clamping and fixing: the annular iron core is wrapped with the rectangular mold frame, the annular iron core is molded into a rectangular iron core by applying certain pressure, and then the iron core is clamped and fixed in a PET binding belt and stainless steel pulling plate mode, so that the integral strength of the iron core is ensured. In order to enable the iron core to be molded completely according to a standard mold, plastic deformation cannot occur due to overlarge pressure, magnetic performance is reduced, and the pressure is controlled within a range of 1-3 MPa.
(4) And (3) step pulse annealing: and (3) placing the rectangular iron core obtained in the step (3) into a vacuum tube annealing furnace, wherein the furnace comprises an electrified straight wire penetrating through the furnace body, and the electrified straight wire penetrates through the iron core and is overlapped with the center of the iron core. In order to prevent the iron core from being seriously oxidized by contact with an oxidant, sulfur-containing or carbon-containing gas, nitrogen containing less than 10% of hydrogen is filled in the furnace as a protective gas, the pressure in the furnace is controlled below 0.07MPa, and a small amount of hydrogen can react with oxygen possibly remained in the nitrogen to generate water for removal. The electrified straight wire has the function of providing an annular electromagnetic field for the iron core so as to ensure that the magnetic moment orientation of the iron core is kept in an easy magnetization direction in the step annealing process, is not influenced by temperature and stress changes, and improves the overall magnetic performance. The wire is fed with pulse current in the annealing process, the current direction is kept unchanged, the pulse frequency is 50-1000 Hz, the current intensity is 5-200A, and the current intensity is increased along with the temperature rise of the annealing furnace. The change pulse current electrifying mode can ensure that the magnetic domain orientation of the iron core does not change obviously along with the temperature rise, improves the magnetic performance, reduces the consumption of electric energy obviously and has strong energy-saving effect.
The temperature rising process is that firstly, the furnace temperature is raised to 400-450 ℃ at a temperature rising rate of 5-10 ℃/min, the temperature is kept for 0.5-1 hour, and the pulse current intensity is 5-50A; and then the furnace temperature is raised to 600-650 ℃ at a heating rate of 3-5 ℃/min, and the temperature is kept for 1-2 hours, and the pulse current intensity is 50-80A. And then slowly heating the furnace temperature to 750-800 ℃ at a heating rate of 1-2 ℃/min, and preserving the heat for 1-2 hours, wherein the pulse current intensity is 80-200A.
After the heat preservation is finished, slowly cooling to 400-500 ℃ at a speed of 0.5-1 ℃/min, wherein the pulse current intensity is 50-200A; finally, cooling the furnace temperature to room temperature at a speed of 1-3 ℃/min, wherein the pulse current intensity is 5-50A.
(5) High-pressure dipping and drying: and (3) sealing the annealed iron core in a paint dipping tank, wherein the paint dipping tank comprises a vacuum valve, a paint conveying valve, a paint returning valve, a pressurizing valve and an air flow valve. Firstly, opening a vacuum valve, vacuumizing to below 50Pa, maintaining for at least 10 minutes, and removing gas in a tank; then closing the vacuum valve, opening the paint conveying valve, slowly inputting the impregnant into the tank until the impregnant is at least 15mm higher than the iron core, and stopping paint conveying to ensure that all parts of the iron core can be soaked, wherein the impregnant is one or more of epoxy end paint, alkyd resin paint and polyester imine impregnating paint mixed with nano-scale fused quartz powder with the mass fraction of more than 10%, and the inorganic filler has the effects of improving the thermal stability of the resin paint, reducing the shrinkage rate of the impregnant after solidification, thereby reducing the internal stress of the iron core and reducing loss; then closing a paint conveying valve, opening a pressurizing valve, pressurizing to 0.5-2 MPa, and keeping for 1-3 hours, wherein under the action of pressure, the impregnant can fully fill micro gaps between the ultrathin oriented silicon steels, so that the overall strength is increased; after the pressurization is finished, the pressure is released to below 0.1MPa, a paint return valve is opened, and under the action of the residual pressure, residual impregnant flows out from the paint return valve; and then closing the paint return valve, opening the air flow valve, introducing pure nitrogen air flow into the tank to dry the iron core, and stopping ventilation after the impregnant on the surface of the iron core is completely dried and solidified to obtain the paint-immersed rectangular iron core.
(6) Shaping: and (3) taking the paint-immersed rectangular iron core obtained in the step (5) out of a paint-immersed tank, removing PET binding belts and stainless steel pulling plates around the iron core, releasing stress generated by a clamp, and finally processing the size and the shape of the iron core to obtain the standard rectangular iron core.
(7) Cutting by using a grinding wheel: and (3) placing the standard rectangular iron core obtained in the step (6) on a special fixture, and tightly binding and solidifying the vicinity of the cut of the standard rectangular iron core by using a glass fiber adhesive tape, wherein the number of the binding turns is not less than 30 turns, so that the grinding and polishing treatment of the end face of the subsequent cut is facilitated. And (3) after curing, using a grinding wheel sheet cutter with the thickness of 1-2 mm to form the rectangular iron core into two C-shaped iron cores at the rotating speed of 2000-3000 r/min. Under the cutting parameters, the surface of the iron core notch is smoother and flatter, and the material consumption is small.
(8) End face grinding and polishing: firstly, placing the C-shaped iron core obtained in the step (7) into a lathe for end face grinding treatment, and removing burrs and oxides remained on the end face in the cutting process. And then soaking the ground end face in an ultrasonic cleaner containing weak acid for at least 5 minutes to remove impurities remained on the end face after grinding. After the pickling is completed, the end face is then flushed with alcohol for at least 1 minute, removing the weak acid solution that may remain. And then the end face is subjected to fine polishing treatment, so that the surface is smooth and has no defects, and after polishing, the high-magnetic-conductivity amorphous alloy or nanocrystalline alloy magnetic conductive adhesive is coated, so that gaps generated during iron core combination can be avoided, loss increase is caused, the magnetic conductivity of a notch can be improved, and the iron core loss is reduced. Finally, carrying out vacuum drying treatment on the end face of the iron core to obtain two C-shaped iron cores with smooth cut end faces.
Example 1
The embodiment provides a method for preparing an iron core by adopting ultrathin oriented silicon steel, which comprises the following steps:
(1) selecting materials: an ultrathin oriented silicon steel strip prepared according to the example 8 of CN 108315542A is selected as a raw material, the thickness of the strip is 0.08mm, and the surface of the strip is coated with an insulating coating with the thickness of 1 mu m.
(2) Cutting and rolling: the raw materials selected in the step (1) are placed into iron core winding equipment, iron core materials are longitudinally sheared into strips with the width of 50mm by a shearing machine, and then the strips are wound into an annular iron core according to the shape of a mould, and the stacking coefficient is 0.95.
(3) And (3) die pressing binding, clamping and fixing: wrapping the annular iron core obtained in the step (2) with a rectangular mold frame, molding the annular iron core into a rectangular iron core by applying pressure of 3MPa, and then clamping and fixing the iron core by adopting a PET binding belt or stainless steel pulling plate mode.
(4) And (3) step pulse annealing: putting the rectangular iron core obtained in the step (3) into a vacuum tube annealing furnace, and adopting nitrogen containing 10% of hydrogen as protective gas, wherein the air pressure in the furnace is kept below 0.07 MPa. The furnace comprises an electrified straight wire penetrating through the furnace body, pulse current is introduced into the wire in the annealing process, the pulse current direction is kept unchanged, the pulse frequency is 50Hz, and the straight wire penetrates through the center of the rectangular iron core. The heating process is that firstly, the furnace temperature is raised to 450 ℃ at the heating rate of 10 ℃/min, the temperature is kept for 1 hour, and the pulse current intensity is 50A; then continuously heating the furnace temperature to 650 ℃ at a heating rate of 5 ℃/min, and preserving the heat for 1 hour, wherein the pulse current intensity is 60A; continuously heating the furnace temperature to 780 ℃ at a heating rate of 1 ℃/min and preserving the heat for 2 hours, wherein the pulse current is 90A; after the heat preservation is finished, slowly cooling to 500 ℃ at a speed of 1 ℃/min, wherein the pulse current is 60A in the cooling process; finally, cooling the furnace temperature to room temperature at a speed of 3 ℃/min, wherein the pulse current is 50A in the cooling process, and obtaining the annealed rectangular iron core.
(5) High-pressure dipping and drying: and (3) sealing the annealed rectangular iron core obtained in the step (4) in a paint dipping tank, wherein the paint dipping tank comprises a vacuum valve, a paint conveying valve, a paint returning valve, a pressurizing valve and an air flow valve. Firstly, opening a vacuum valve, vacuumizing to below 50Pa, and keeping for 10 minutes; then closing the vacuum valve, opening the paint conveying valve, slowly inputting the impregnant into the tank until the impregnant is about 15mm higher than the iron core, stopping paint conveying, wherein the impregnant is epoxy resin end paint mixed with 10% of nano fused quartz powder by mass, then closing the paint conveying valve, opening the pressurizing valve, pressurizing to 2MPa, and maintaining for 1 hour; after the pressurization is finished, the pressure is released to below 0.1MPa, and a paint return valve is opened to enable residual impregnant to flow out of the paint return valve; and then closing the paint return valve, opening the air flow valve, introducing pure nitrogen into the tank to dry the iron core, and stopping ventilation after the impregnant on the surface of the iron core is completely dried and solidified to obtain the paint-immersed rectangular iron core.
(6) Shaping the iron core: and (3) taking the paint-immersed rectangular iron core obtained in the step (5) out of a paint-immersed tank, removing PET binding belts and stainless steel pulling plates around the iron core, and finally processing the size and shape of the iron core to obtain a standard rectangular iron core.
(7) The concrete process of the iron core grinding wheel cutting is as follows: and (3) placing the standard rectangular iron core obtained in the step (6) on a special fixture, binding and solidifying the vicinity of a notch before cutting the iron core by using a glass fiber adhesive tape, wherein the number of turns of the glass fiber adhesive tape is 30, and cutting the rectangular iron core into two C-shaped iron cores by using a grinding wheel sheet cutter with the thickness of 1mm at the rotating speed of 2500r/min after solidification.
(8) End face grinding and polishing: firstly, placing the C-shaped iron core obtained in the step (7) into a lathe for end face grinding treatment, then soaking the ground end face in an ultrasonic cleaner containing weak acid for cleaning for 5 minutes, after the acid cleaning is finished, flushing the end face with alcohol for 1 minute, then carrying out finish polishing, brushing nanocrystalline magnetic conductive adhesive and vacuum drying treatment on the end face, and finally obtaining the two C-shaped iron cores with smooth cut end faces.
Example 2
This example is essentially the same as example 1, except (1) the material is selected from: an ultrathin oriented silicon steel strip prepared according to the example 6 of CN 108315542A is selected as a raw material, the thickness of the strip is 0.1mm, and the surface of the strip is coated with an insulating coating with the thickness of 2 mu m.
Example 3
The embodiment provides a method for preparing an iron core by adopting ultrathin oriented silicon steel, which comprises the following steps:
(1) selecting iron core materials: an ultrathin oriented silicon steel strip prepared according to the example 8 of CN 108315542A is selected as a raw material, the thickness of the strip is 0.08mm, and the surface of the strip is coated with an insulating coating with the thickness of 1 mu m.
(2) Cutting and rolling: the core material was put into a core winding apparatus, which was first slit into strips of 50mm in width by a shears, and then wound into a toroidal core in the shape of a die with a stacking factor of 0.95.
(3) And (3) die pressing binding, clamping and fixing: wrapping the annular iron core obtained in the step (2) with a rectangular mold frame, molding the annular iron core into a rectangular iron core by applying pressure of 3MPa, and then clamping and fixing the iron core by adopting a PET binding belt or stainless steel pulling plate mode.
(4) And (3) step pulse annealing: putting the rectangular iron core obtained in the step (3) into a vacuum tube annealing furnace, and adopting nitrogen containing 10% of hydrogen as protective gas, wherein the air pressure in the furnace is kept below 0.07 MPa. The furnace comprises an electrified straight wire penetrating through the furnace body, pulse current is introduced into the wire in the annealing process, the pulse current direction is kept unchanged, the pulse frequency is 1000Hz, and the straight wire penetrates through the center point of the rectangular iron core. The temperature rising process is that firstly, the furnace temperature is raised to 400 ℃ at a temperature rising rate of 5 ℃/min, the temperature is kept for 0.5 hour, and the pulse current intensity is 5A; then continuously heating the furnace temperature to 600 ℃ at a heating rate of 3 ℃/min, and preserving the heat for 2 hours, wherein the pulse current intensity is 50A; then continuously heating the furnace temperature to 800 ℃ at a heating rate of 2 ℃/min and preserving the temperature for 1 hour, wherein the pulse current is 200A; after the heat preservation is finished, slowly cooling to 400 ℃ at the speed of 0.5 ℃/min, wherein the pulse current is 50A; and finally cooling the furnace temperature to room temperature at a speed of 1 ℃/min, wherein the pulse current is 5A, and obtaining the annealed rectangular iron core.
(5) High-pressure dipping and drying: and (3) sealing the annealed rectangular iron core obtained in the step (4) in a paint dipping tank, wherein the paint dipping tank comprises a vacuum valve, a paint conveying valve, a paint returning valve, a pressurizing valve and an air flow valve. Firstly, opening a vacuum valve, vacuumizing to below 50Pa, and keeping for 10 minutes; then closing the vacuum valve, opening the paint conveying valve, slowly inputting the impregnant into the tank until the impregnant is about 15mm higher than the iron core, stopping paint conveying, wherein the impregnant is alkyd resin paint mixed with 10% of nano fused quartz powder by mass, then closing the paint conveying valve, opening the pressurizing valve, pressurizing to 0.5MPa, and maintaining for 3 hours; after the pressurization is finished, the pressure is released to below 0.1MPa, and a paint return valve is opened to enable residual impregnant to flow out of the paint return valve; and then closing the paint return valve, opening the air flow valve, introducing pure nitrogen into the tank to dry the iron core, and stopping ventilation after the impregnant on the surface of the iron core is completely dried and solidified to obtain the paint-immersed rectangular iron core.
(6) Shaping the iron core: and (3) taking the paint-immersed rectangular iron core obtained in the step (5) out of a paint-immersed tank, removing PET binding belts and stainless steel pulling plates around the iron core, and finally processing the size and shape of the iron core to obtain a standard rectangular iron core.
(7) The concrete process of the iron core grinding wheel cutting is as follows: and (3) placing the standard rectangular iron core obtained in the step (6) on a special fixture, binding and solidifying the vicinity of a notch before cutting the iron core by using a glass fiber adhesive tape, wherein the number of turns of the glass fiber adhesive tape is 30, and cutting the rectangular iron core into two C-shaped iron cores by using a grinding wheel sheet cutter with the thickness of 1mm at the rotating speed of 2500r/min after solidification.
(8) End face grinding and polishing: firstly, placing the C-shaped iron core obtained in the step (7) into a lathe for end face grinding treatment, then soaking the ground end face in an ultrasonic cleaner containing weak acid for cleaning for 5 minutes, after the acid cleaning is finished, flushing the end face with alcohol for 1 minute, then carrying out finish polishing, brushing nanocrystalline magnetic conductive adhesive and vacuum drying treatment on the end face, and finally obtaining the two C-shaped iron cores with smooth cut end faces.
Comparative example 1
This comparative example is substantially the same as example 1 except that the iron core is composed of high magnetic induction oriented silicon steel (trade name B18R 065) having a thickness of 0.18 mm.
Comparative example 2
This comparative example is substantially the same as example 1 except that the pulse current is not used in the step pulse annealing process of (4) in this comparative example.
Comparative example 3
This comparative example is substantially the same as example 1 except that a pulse current having a constant current intensity of 200A was always added during the step pulse annealing in (4) of this comparative example.
The transformers or reactor cores prepared in examples 1 to 3 and comparative examples 1 to 3 were tested for loss and noise at magnetic flux densities of 1.0T, frequencies of 600Hz and 1000Hz, respectively, using a soft magnetic measurement system and a noise meter, and the test results are shown in table 1.
Table 1 results of transformer core loss and noise tests
As can be seen from the table, the test results of examples 1-3 and comparative examples 1-3 show that the ultra-thin oriented silicon steel core with the thickness less than or equal to 0.10mm has the loss of less than 15.0W/kg under the conditions of the magnetic flux density of 1.0T and the working frequency of 600Hz and the loss of less than 22.5W/kg under the conditions of the magnetic flux density of 1.0T and the working frequency of 1000Hz. The design of the ultrathin oriented silicon steel iron core and the adoption of a graded pulse annealing mode can remarkably reduce the loss of the iron core, the magnetic density is higher, the volume and the weight can be smaller, and the method is more suitable for being used at medium and high frequencies.
In terms of noise, the noise value of the iron core of the invention is 67dB (A) at the frequency of 600Hz and 1000Hz, and the noise reduction effect is obvious.
It is apparent that the above examples are given by way of illustration only and are not limiting of the embodiments. Other variations or modifications of the above teachings will be apparent to those of ordinary skill in the art. It is not necessary here nor is it exhaustive of all embodiments. And obvious variations or modifications thereof are contemplated as falling within the scope of the present invention.
Claims (11)
1. A method for preparing an iron core by adopting ultrathin oriented silicon steel is characterized by comprising the following steps:
step 1, selecting ultrathin oriented silicon steel with the thickness less than or equal to 0.10mm as a raw material;
step 2, cutting the ultrathin oriented silicon steel into strips according to the width requirement of the iron core, and winding the strips into the iron core;
step 3, clamping and fixing the iron core;
step 4, placing the fixed iron core into a vacuum tube type heat treatment furnace, and carrying out graded pulse annealing treatment on the iron core in a pulse current mode with unchanged direction, wherein the pulse current intensity is increased along with the increase of the annealing temperature;
the temperature rising process of the graded pulse annealing treatment is that firstly, the furnace temperature is raised to 400-450 ℃ at a temperature rising rate of 5-10 ℃/min, the temperature is kept for 0.5-1 hour, and the pulse current intensity is 5-50A; then, the furnace temperature is raised to 600-650 ℃ at a heating rate of 3-5 ℃/min, and the temperature is kept for 1-2 hours, and the pulse current intensity is 50-80A; then slowly heating the furnace temperature to 750-800 ℃ at a heating rate of 1-2 ℃/min, and preserving the heat for 1-2 hours, wherein the pulse current intensity is 80-200A;
and 5, dipping and drying the iron core subjected to the graded pulse annealing.
2. The method for manufacturing an iron core by using ultra-thin oriented silicon steel according to claim 1, wherein in the step 4, the pulse current pulse frequency of the graded pulse annealing is 50-1000 hz.
3. The method for manufacturing an iron core using ultra-thin oriented silicon steel as set forth in claim 1, wherein,
the graded pulse anneal further comprises: and (5) cooling.
4. The method of manufacturing an iron core using ultra-thin oriented silicon steel as set forth in claim 3, wherein the cooling comprises:
cooling the furnace temperature to 400-500 ℃ under the condition of applying 50-200A pulse current;
and then cooling the furnace temperature to room temperature under the condition of applying 5-50A pulse current.
5. The method for manufacturing an iron core using ultra-thin oriented silicon steel as set forth in claim 4, wherein at least one of the following conditions is satisfied:
(1) Reducing the furnace temperature to 400-500 ℃ at a cooling rate of 0.5-1 ℃/min;
(2) And cooling the furnace temperature to room temperature at a cooling rate of 1-3 ℃/min.
6. The method for manufacturing an iron core using ultra-thin oriented silicon steel as set forth in any one of claims 1 to 5, wherein the step 5 includes: placing the iron core into an impregnation tank, introducing an impregnating agent into the impregnation tank to submerge the iron core, and impregnating under the action of pressure; the impregnant is extracted, and air flow is introduced to dry the iron core.
7. The method for manufacturing an iron core using ultra-thin oriented silicon steel as claimed in claim 6, wherein the pressure is 0.5 to 2mpa and the dipping time is 1 to 3 hours.
8. The method for manufacturing an iron core using ultra-thin oriented silicon steel as set forth in any one of claims 1 to 5, further comprising the steps of shaping, grinding wheel cutting, and end face grinding and polishing after step 5.
9. The method for manufacturing an iron core using ultra-thin oriented silicon steel as claimed in any one of claims 1 to 5, wherein the ultra-thin oriented silicon steel is coated with an insulating coating having a thickness of 1 to 2 μm.
10. A core made according to the method of any one of claims 1-9.
11. Use of the core of claim 10 in a transformer or a reactor.
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