CN117912805A - Transformer, three-dimensional wound core and manufacturing method thereof - Google Patents

Abstract

The application relates to a transformer and a three-dimensional wound iron core and a manufacturing method thereof, wherein the three-dimensional wound iron core comprises three iron core single frames, each iron core single frame comprises a material belt and two adjacent soft magnetic materials, each iron core single frame comprises an iron yoke part and an iron core column part, and the three iron core single frames are wound and connected at the iron core column part through a tightening belt so as to form the three-dimensional wound iron core with a regular triangle three-dimensional cross section; soft magnetic materials are placed at the soft iron yoke part in the interval multi-layer material belts of each iron core single frame, and two adjacent soft magnetic materials are distributed at intervals of the multi-layer material belts. The three-dimensional wound iron core is formed by three iron core single frames with identical structures, the iron core single frames are formed by continuously winding a plurality of material strips, and a certain proportion of soft magnetic materials are inserted into the iron yoke parts of the iron core single frames, so that the effective sectional area of the iron yoke of the iron core single frames is increased, and the aim of reducing the magnetic density of the iron yoke of the three-dimensional wound iron core is achieved; the three-dimensional wound iron core can effectively reduce the magnetic density of the iron yoke and avoid the supersaturation phenomenon of the magnetic density of the iron yoke on the premise of not changing the magnetic density of the iron core column.

Description

Transformer, three-dimensional wound core and manufacturing method thereof

Technical Field

The application relates to the technical field of iron cores, in particular to a transformer, a three-dimensional wound iron core and a manufacturing method thereof.

Background

At present, the traditional three-dimensional wound iron core is formed by splicing three iron core single frames which are identical in section and are formed by continuously winding silicon steel sheets in pairs, so that the three-dimensional wound iron core has the advantages of three-phase balance, low no-load loss, low no-load current, low noise, low cost and the like.

The magnetic density of the iron yoke part of the existing three-dimensional wound iron core is 1.155 times of that of the iron core column, when the magnetic density of the iron core column is B, the magnetic density of the iron yoke part is 1.155B, however, the oversaturation phenomenon can be caused by the overhigh magnetic density of the iron yoke part of the three-dimensional wound iron core, and the no-load loss of the iron core is further increased.

Disclosure of Invention

The embodiment of the application provides a transformer, a three-dimensional wound core and a manufacturing method thereof, which are used for solving the technical problem that the existing three-dimensional wound core structure has the magnetic density supersaturation phenomenon of an iron yoke.

In order to achieve the above object, the embodiment of the present application provides the following technical solutions:

in one aspect, a three-dimensional wound iron core is provided, including three iron core single frames, each iron core single frame includes a material strip and two adjacent soft magnetic materials, each iron core single frame includes an iron core column part formed by winding the material strip, wherein the iron core column parts are arranged up and down and two iron core column parts are arranged left and right, and the three iron core single frames are connected in a winding way through a tightening strip, so that a three-dimensional wound iron core with a regular triangle three-dimensional cross section is formed;

One soft magnetic material is placed at the soft iron yoke part in the interval multi-layer material belt of each iron core single frame, and two adjacent soft magnetic materials are distributed in the interval multi-layer material belt.

Preferably, the material belt is made of silicon steel material or amorphous alloy material, and the soft magnetic material is silicon steel material or amorphous alloy material.

Preferably, two adjacent layers of the material belts are distributed in a staggered manner along the width direction, and the width of the material belts gradually decreases from the middle to the two ends, so that one side of the iron core single frame forms a plane, and the other side of the iron core single frame forms an arc surface.

Preferably, the angle between the plane and the material strip is 60 °.

Preferably, the lengths of two adjacent soft magnetic materials are gradually increased along the direction away from the center of the material belt, and the widths of two adjacent soft magnetic materials are gradually reduced from the middle to two ends, so that the soft magnetic materials correspond to the widths of the material belt.

In still another aspect, a method for manufacturing a three-dimensional wound core is provided, which is applied to the three-dimensional wound core, and includes the following steps:

acquiring magnetic density parameter and sectional area increasing data of the three-dimensional wound iron core, and processing the three-dimensional wound iron core into a plurality of material strips with widths gradually reduced from the middle to two ends by adopting silicon steel materials or amorphous alloy materials;

Determining the quantity of the soft magnetic materials according to the magnetic density parameters and the sectional area increasing data, and calculating the winding layer number of the soft magnetic materials placed on the material belt according to the sectional area increasing data;

One end of the material belt is fixed on a core mold, and the core mold is driven to rotate so as to drive the material belt to wind along the circumferential direction of the core mold; when the number of winding layers reaches the number of winding layers, placing a piece of soft magnetic material at the position of the iron yoke until the number of soft magnetic materials is completely placed, and winding the material strip according to the number of winding layers to obtain an iron core single frame;

And winding and connecting the three iron core single frames with the same structure on the iron core column parts of the iron core single frames through tightening belts so as to form the three-dimensional wound iron core with the regular-triangle three-dimensional cross section.

Preferably, the method of manufacturing the three-dimensional wound core includes: when the mandrel is driven to rotate so as to drive the material belt to wind along the circumferential direction of the mandrel, one side of the material belt is abutted through the limiting piece, so that the material belt moves along the width direction of the material belt, and two adjacent layers of material belts are distributed in a staggered mode.

Preferably, calculating the number of winding layers of the soft magnetic material placed on the material tape according to the sectional area increase data includes: the inverse of the cross-sectional area increase data is used as the number of winding layers of the soft magnetic material placed on the material belt.

Preferably, the magnetic flux density parameter includes a magnetic flux density of an iron yoke of the three-dimensional wound core, a magnetic flux density limit value of the iron yoke, and a specification size of the soft magnetic material, and determining the amount of the soft magnetic material according to the magnetic flux density parameter and the sectional area increase data includes:

determining the iron yoke increasing area multiple of the three-dimensional wound iron core according to the ratio of the iron yoke magnetic density to the iron yoke magnetic density value;

and determining the quantity of the soft magnetic materials according to the iron yoke increase area multiple, the soft magnetic material specification size and the sectional area increase data.

In yet another aspect, a transformer is provided, including the three-dimensional wound core described above.

The three-dimensional wound iron core comprises three iron core single frames, wherein each iron core single frame comprises a material belt and two adjacent soft magnetic materials, each iron core single frame comprises an iron core column part formed by winding the material belt, wherein the iron yoke parts are arranged up and down, and the iron core column parts are arranged left and right, and the three iron core single frames are connected in a winding way through tightening belts at the iron core column parts so as to form the three-dimensional wound iron core with a regular triangle three-dimensional cross section; wherein, soft iron yoke portion department places a soft magnetic material in every single frame of iron core interval multilayer material area, and adjacent two soft magnetic material interval multilayer material area distributes. From the above technical solutions, the embodiment of the present application has the following advantages: the three-dimensional wound iron core is formed by winding iron core column parts of each iron core single frame through tightening belts, wherein the splicing cross sections of the iron core column parts of each iron core single frame are in a regular triangle, each iron core single frame is continuously wound by a plurality of material belts, soft magnetic materials with a certain proportion are inserted into iron yoke parts of the iron core single frames, and the effective cross section of an iron yoke of the three-dimensional wound iron core is increased, so that the aim of reducing the magnetic density of the iron yoke of the three-dimensional wound iron core is fulfilled; therefore, the three-dimensional wound iron core can effectively reduce the magnetic density of the iron yoke on the premise of not changing the magnetic density of the iron core column, avoid the supersaturation phenomenon of the magnetic density of the iron yoke, and further promote the no-load loss of the three-dimensional wound iron core to be correspondingly reduced; solves the technical problem that the prior three-dimensional wound core structure has the magnetic density supersaturation phenomenon of an iron yoke.

Drawings

In order to more clearly illustrate the embodiments of the application or the technical solutions of the prior art, the drawings which are used in the description of the embodiments or the prior art will be briefly described, it being obvious that the drawings in the description below are only some embodiments of the application, and that other drawings can be obtained according to these drawings without inventive faculty for a person skilled in the art.

Fig. 1 is a schematic perspective view of a three-dimensional wound core according to an embodiment of the present application;

fig. 2 is a schematic view of a partial cross-sectional structure of a core single frame in a three-dimensional wound core according to an embodiment of the present application;

fig. 3 is a schematic structural diagram of a single frame of an iron core in a stereoscopic coil iron core according to an embodiment of the present application;

Fig. 4 is a schematic structural diagram of a material strip in a stereoscopic coil core according to an embodiment of the present application;

fig. 5 is a schematic cross-sectional view of a single frame of a three-dimensional wound core according to an embodiment of the present application;

fig. 6 is a schematic top view of a three-dimensional wound core according to an embodiment of the present application;

fig. 7 is a flowchart illustrating steps of a method for manufacturing a three-dimensional wound core according to an embodiment of the present application;

fig. 8 is a schematic view of a structure of a material tape winding in a method for manufacturing a three-dimensional wound core according to an embodiment of the present application.

Detailed Description

In order to make the objects, features and advantages of the present application more comprehensible, the following description of the embodiments accompanied with the accompanying drawings in the embodiments of the present application will make it apparent that the embodiments described below are only some embodiments but not all embodiments of the present application. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.

In the description of embodiments of the present application, the terms "first," "second," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include one or more such feature. In the description of the embodiments of the present application, the meaning of "plurality" is two or more, unless explicitly defined otherwise.

In the embodiments of the present application, unless explicitly specified and limited otherwise, the terms "mounted," "connected," "secured" and the like are to be construed broadly and include, for example, either permanently connected, removably connected, or integrally formed; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communicated with the inside of two elements or the interaction relationship of the two elements. The specific meaning of the above terms in the embodiments of the present application will be understood by those of ordinary skill in the art according to specific circumstances.

The embodiment of the application provides a transformer, a three-dimensional wound core and a manufacturing method thereof, which solve the technical problem that the existing three-dimensional wound core structure has the magnetic density supersaturation phenomenon of an iron yoke.

Embodiment one:

Fig. 1 is a schematic perspective view of a three-dimensional wound core according to an embodiment of the present application, fig. 2 is a schematic partially cross-sectional view of a single frame of the core in the three-dimensional wound core according to an embodiment of the present application, and fig. 3 is a schematic structural view of a single frame of the core in the three-dimensional wound core according to an embodiment of the present application.

As shown in fig. 1 to 3, an embodiment of the present application provides a three-dimensional wound core including: each iron core single frame 100 comprises a material belt 200 and two adjacent soft magnetic materials 300, each iron core single frame 100 comprises two iron yoke parts 110 arranged up and down and two iron leg parts 120 arranged left and right formed by winding 200 material belts, and the three iron core single frames 100 are connected with each other by winding the iron leg parts 120 through tightening belts so as to form a three-dimensional wound iron core with a regular triangle three-dimensional cross section. Wherein, a piece of soft magnetic material 300 is placed at the soft iron yoke 110 in the interval multi-layer material belt 200 of each iron core single frame 100, and two adjacent pieces of soft magnetic material 300 are distributed at intervals of the multi-layer material belt 200.

It should be noted that, the material strip 200 may be made of silicon steel material or amorphous alloy material to improve the magnetic permeability of the material strip 200. The angle between two adjacent core single frames 100 is 60 °.

In the embodiment of the present application, the structure having the iron yoke 110 and the core leg 120 is formed by winding the tape 200, and a single core single frame 100 is formed by placing a piece of soft magnetic material 300 at intervals of plural layers of the tape 200 at the iron yoke 110. The number of the soft magnetic material tapes 300 in each core single frame 100 is determined according to the design requirement of the yoke flux density and the yoke flux density limit value, and is not particularly limited herein. The shape of the single core frame 100 may be set according to requirements, and as shown in fig. 3, the shape of the single core frame 100 is a rounded rectangular shape.

It should be noted that, the three-dimensional wound iron core is formed by winding three iron core single frames 100 with identical structures through tightening belts and splicing cross sections of iron core column parts 120 of each iron core single frame 100 into a regular triangle, each iron core single frame 100 is continuously wound by a plurality of material belts 200, and in the winding process of the iron core single frame 100, a certain proportion of soft magnetic materials 300 are inserted at the iron yoke part 110 of the iron core single frame 100, so that the effective cross section of the iron yoke of the three-dimensional wound iron core is increased, and the aim of reducing the magnetic density of the iron yoke of the three-dimensional wound iron core is achieved. Therefore, the three-dimensional wound iron core can effectively reduce the magnetic density of the iron yoke on the premise of not changing the magnetic density of the iron core column, avoid the supersaturation phenomenon of the magnetic density of the iron yoke, further reduce the no-load loss of the iron core, and exert the advantages of the three-dimensional wound iron core, thereby promoting the development and application of the three-dimensional wound iron core technology.

The application provides a three-dimensional wound iron core, which comprises three iron core single frames, wherein each iron core single frame comprises a material belt and two adjacent soft magnetic materials, each iron core single frame comprises an iron yoke part and an iron core column part, wherein the iron yoke parts are arranged up and down and the iron core column parts are arranged left and right, the iron core single frames are wound and connected at the iron core column parts through tightening belts, so that a three-dimensional wound iron core with a regular triangle three-dimensional cross section is formed; wherein, soft iron yoke portion department places a soft magnetic material in every single frame of iron core interval multilayer material area, and adjacent two soft magnetic material interval multilayer material area distributes. The three-dimensional wound iron core is formed by winding iron core column parts of each iron core single frame through tightening belts, wherein the splicing cross sections of the iron core column parts of each iron core single frame are in a regular triangle, each iron core single frame is continuously wound by a plurality of material belts, soft magnetic materials with a certain proportion are inserted into iron yoke parts of the iron core single frames, and the effective cross section of an iron yoke of the three-dimensional wound iron core is increased, so that the aim of reducing the magnetic density of the iron yoke of the three-dimensional wound iron core is fulfilled; therefore, the three-dimensional wound iron core can effectively reduce the magnetic density of the iron yoke and avoid the supersaturation phenomenon of the magnetic density of the iron yoke on the premise of not changing the magnetic density of an iron core column; solves the technical problem that the prior three-dimensional wound core structure has the magnetic density supersaturation phenomenon of an iron yoke.

Fig. 4 is a schematic structural diagram of a material strip in a stereoscopic rolled iron core according to an embodiment of the present application, and fig. 5 is a schematic sectional structural diagram of a single frame of the iron core in the stereoscopic rolled iron core according to an embodiment of the present application.

As shown in fig. 2 to 4, in one embodiment of the present application, two adjacent layers of tapes 200 are staggered in the width direction, and the width of the tapes 200 gradually decreases from the middle to both ends, so that one side of the core single frame 100 forms a plane 210 and the other side of the core single frame 100 forms a cambered surface 220.

It should be noted that, the adjacent two layers of the material tapes 200 are distributed in a staggered manner along the width direction, so that after the material tapes 200 between the layers are staggered and overlapped in the winding process, the cross-sectional area of the single core frame 100 is increased, and the single core frame 100 is convenient to be magnetized in the use process so as to perform normal operation. The width of the tape 200 gradually decreases from the middle toward both ends. As shown in fig. 3 and 4, the material strip 200 includes a plurality of sections, each of which is arranged in a right-angle trapezoidal shape, so that one side of the core single frame 100 can be formed with a plane 210, and the other side is formed with an arc surface 220, thereby making the section of the core limb portion 120 be in an approximately circular polygonal structure. The material section is arranged in a right-angle trapezoid shape, so that the filling coefficient of the section of the iron core is 96-97%. If the three-dimensional wound core is used for manufacturing a transformer as a case description, the three-dimensional wound core has the following beneficial effects:

First, under the condition that the cross-sectional diameter of the leg portion 120 is not changed, as shown in A-A of fig. 5, the higher filling factor makes the cross-section of the leg portion 120 more circular, reducing the gap between the core single frame 100 and the wound coil. By utilizing the property that the circular cross section is uniformly stressed, when the force acted on the cross section of the iron core column part 120 which tends to be circular acts on the circumference of the iron core column part, the stress is uniformly distributed on the circumference, namely the force acted on each material section tends to be equal, so that the transformer can be better kept stable under the action of short-circuit electric force, and the burst short-circuit resistance of the transformer is improved;

Secondly, under the condition that the cross-sectional diameter of the iron yoke 110 is unchanged, the higher filling coefficient can further obtain a larger effective cross-sectional area, so that the magnetic density of the iron yoke 110 is further reduced, and the no-load loss of the three-dimensional wound core is further reduced correspondingly;

And under the condition that the effective sectional area of the three-dimensional wound core is unchanged, the smaller diameter can be selected by the higher filling coefficient when the electromagnetic scheme of the transformer is designed, so that the length of a coil wire can be reduced, raw materials such as copper materials can be saved, the load loss can be reduced, and the energy-saving material can be realized.

As shown in fig. 4, in the embodiment of the present application, the material belt 200 includes a material section A1-A6, where the section widths of the material sections A1-A6 gradually decrease from the middle to both ends, which can be understood as: the width of the middle material section is large, and the width of the two end material sections is small. The material section A1 is an inner layer of the single core frame 100, the material section A2 is an outer layer of the material section A1, and so on, so that the material section A6 is an outer layer of the single core frame 100. The head width of the material section A2 is equal to the tail width of the material section A1, the head width of the material section A3 is equal to the tail width of the material section A2, and the like, so that the material sections can be connected in a seamless manner.

Fig. 6 is a schematic top view of a three-dimensional wound core according to an embodiment of the present application.

In one embodiment of the application, as shown in fig. 6, the angle between the plane 210 and the strip 200 is 60 °.

It should be noted that, the included angle between the plane 210 and the material tape 200 is 60 °, so that the two core single frames 100 form an included angle of 60 ° by the planes 210 at the core leg portions 120 of the two core single frames 100 abutting each other.

In one embodiment of the present application, the lengths of two adjacent pieces of soft magnetic material 300 gradually increase in sequence in a direction away from the winding center of the tape 200, and the widths of the two adjacent pieces of soft magnetic material 300 gradually decrease from the middle toward both ends, so that the soft magnetic material 300 corresponds to the width of the tape 200.

At the iron yoke 110 of the spacer multilayer material tape 200, a piece of soft magnetic material 300 for increasing the cross-sectional area of the iron yoke 110 is provided. Two adjacent blocks of soft magnetic material 300 are arranged on the iron core single frame 100. In some embodiments, soft magnetic material 300 may be preferentially selected to be a silicon steel material or an amorphous alloy material. Since the magnetic density of the iron yoke 110 is 1.155 times that of the core limb portion 120, the magnetic density of the iron yoke 110 is reduced by increasing the cross-sectional area of the iron yoke 110, thereby reducing the no-load loss of the core single frame 100. The single piece of soft magnetic material 300 is disposed between two adjacent layers of the material strips 200, and the adjacent two pieces of soft magnetic material 300 are distributed with the multiple layers of material strips 200 spaced apart so that the cross-sectional area of the iron yoke 110 is uniformly increased. Along the direction away from the winding center of the material strip 200, the lengths of two adjacent soft magnetic materials 300 are gradually increased, and the width of each soft magnetic material 300 is gradually reduced from the middle to two ends, so that the width of the soft magnetic material strip 300 corresponds to the width of the material strip 200, and the circumference of the iron core single frame 100 is continuously increased during the winding process of the material strip 200, so that the material strip 200 of the iron yoke 110 is continuously increased, so that the length of the soft magnetic material 300 correspondingly changes according to the change of the length of the material strip 200, and the situation that gaps occur between two layers of material strips 200 is reduced.

Embodiment two:

Fig. 7 is a flowchart illustrating steps of a method for manufacturing a three-dimensional wound core according to an embodiment of the present application, and fig. 8 is a schematic diagram illustrating a structure of a tape winding in the method for manufacturing a three-dimensional wound core according to an embodiment of the present application.

As shown in fig. 7 and 8, an embodiment of the present application provides a method for manufacturing a three-dimensional wound core, which is applied to the three-dimensional wound core, and includes the following steps:

S1, acquiring magnetic density parameter and sectional area increasing data of a three-dimensional wound iron core, and processing the three-dimensional wound iron core into a plurality of material strips with widths gradually reduced from the middle to two ends by adopting silicon steel materials or amorphous alloy materials.

In step S1, parameters including the magnetic density parameter, the sectional area increase data, and the soft magnetic material specification size, which are required to manufacture the three-dimensional wound core, are acquired. Secondly, a material belt for manufacturing the single frame of the iron core is obtained. In this embodiment, a silicon steel material (such as a silicon steel sheet) may be processed into one or more strips with a curved shape according to a curve.

S2, determining the quantity of the soft magnetic materials according to the magnetic density parameters and the sectional area increasing data, and calculating the winding layer number of the soft magnetic materials placed on the material belt according to the sectional area increasing data.

In step S2, the size and the number of soft magnetic materials for manufacturing the three-dimensional wound core are determined according to the magnetic density parameter of the three-dimensional wound core set in step S1, and the number of winding layers of soft magnetic materials placed on the material tape during manufacturing the three-dimensional wound core is calculated according to the sectional area increase data in step S1. Providing material and manufacturing data for subsequent fabrication of the three-dimensional wound core. Wherein, soft magnetic material can be selected as the silicon steel sheet that tailors and matches with the material area.

S3, fixing one end of the material belt on a core mold, and driving the core mold to rotate so as to drive the material belt to wind along the circumferential direction of the core mold; when the number of winding layers reaches the number of winding layers, a piece of soft magnetic material is placed at the iron yoke part until the number of soft magnetic materials is completely placed, and then the material is wound according to the number of winding layers to obtain the iron core single frame.

It should be noted that, as shown in fig. 8, the limiting member has elastic potential energy when abutting against the material belt 200, so that the limiting member can keep the moving position of the material belt 200 away when the mandrel 400 rotates by using elastic force, and meanwhile, keeps the abutting pressure on the material belt 200, so as to guide the material belt 200 to be distributed in a staggered manner along the width direction. In this embodiment, the material strip processed in step S1 is continuously wound into a single core single frame, and the soft magnetic material cut in step S2 is inserted into the designed winding layer number at the yoke portion wound to the single core single frame during the winding process of the material strip until the soft magnetic material with the amount determined in step S2 is placed on the core single frame to manufacture one core single frame.

S4, winding and connecting the three iron core single frames with the same structure on the iron core column parts of the iron core single frames through tightening belts so as to form the three-dimensional wound iron core with the regular triangle three-dimensional cross section.

In step S4, three independent single iron core frames having the same structure are respectively assembled into a three-dimensional wound iron core in 60. The three iron core single frames are mutually matched in pairs, and then are tightly wound in the core column area by using a tightening belt.

In an embodiment of the present application, the method for manufacturing the three-dimensional wound core includes: when the mandrel is driven to rotate so as to drive the material belts to wind along the circumferential direction of the mandrel, one sides of the material belts are abutted through the limiting piece, so that the material belts move along the width direction of the material belts, and two adjacent layers of material belts are distributed in a staggered mode.

In the embodiment of the application, calculating the winding layer number of the soft magnetic material placed on the material belt according to the sectional area increase data comprises the following steps: the inverse of the cross-sectional area increase data is used as the number of winding layers of soft magnetic material placed on the tape.

When the sectional area increase data of the three-dimensional wound core was set to 12.5%, the number of winding layers of the soft magnetic material placed on the tape was calculated to be 1/12.5% =8. In this embodiment, eight layers of the material strips 200 are spaced between two adjacent soft magnetic materials 300, so that the cross-sectional area of the iron yoke 110 is increased by 12.5%, and the magnetic density of the iron yoke 110 can be correspondingly reduced, so that the magnetic density of the iron yoke 110 is the same as that of the iron core limb 120, and the problem of supersaturation caused by over-high magnetic density of the iron yoke 110 is further reduced. Referring to fig. 5, A-A is a cross section of the leg portion 120, and B-B is a cross section of the yoke portion 110 after the soft magnetic material 300 is placed, it is apparent that the cross section of the B-B is larger than the cross section of the A-A portion, so as to achieve an effect of increasing the cross section of the yoke portion 110. In step S3, a piece of soft magnetic material 300 is placed at intervals of eight layers of the tape 200, so that the cross-sectional area of the iron yoke 110 is increased by 12.5%, and the magnetic density of the iron yoke 110 is reduced as required without changing the magnetic density of the iron leg 120.

In the embodiment of the application, the magnetic flux density parameters comprise the magnetic flux density of the iron yoke of the three-dimensional wound iron core, the magnetic flux density limit value of the iron yoke and the specification and the size of the soft magnetic material, and determining the quantity of the soft magnetic material according to the magnetic flux density parameters and the sectional area increase data comprises the following steps: determining the iron yoke increasing area multiple of the three-dimensional wound iron core according to the ratio of the iron yoke magnetic density to the iron yoke magnetic density value; the number of soft magnetic materials is determined according to the area increasing multiple of the iron yoke, the specification size of the soft magnetic materials and the sectional area increasing data.

When the core column density of the three-dimensional wound core is B, the yoke density is 1.155B, and the yoke density value B 'is set, and the yoke increase area multiple S1 is 1.155B/B'. Under the condition that other conditions are unchanged, the iron yoke increasing area multiple S1 is the multiple of the area of the three-dimensional wound iron core in the iron yoke, and the number of soft magnetic materials required to be inserted into the iron yoke is calculated through the iron yoke increasing area multiple S1. In this embodiment, when the magnetic density of the iron yoke 110 of the three-dimensional wound core needs to be reduced, the number of soft magnetic materials 300 is calculated in step S2, when the material tape 200 is wound and when the iron yoke 110 is directed upward, a single piece of soft magnetic materials 300 is placed on the iron yoke 110, the above step S3 is repeated until the material tape 200 is wound into the iron core single frame 100 according to the number of winding layers calculated in step S2, and three identical iron core single frames 100 are spliced into the three-dimensional wound core, thereby uniformly increasing the cross-sectional area of the iron yoke 110, further reducing the magnetic density of the iron yoke 110 without changing the magnetic density of the iron core limb 120, thereby reducing the problem of supersaturation caused by the magnetic density of the iron yoke 110, and further reducing the no-load loss of the three-dimensional wound core.

In the embodiment of the application, the content of the number of the inserted soft magnetic materials needed by the iron yoke is calculated by increasing the area multiple S1 of the iron yoke is as follows: if the sectional area increase data is 12.5%, the specification and the size of the soft magnetic material include the thickness h and the width L1 of the soft magnetic material, and the amount of the soft magnetic material required to be inserted into the iron yoke is n=12.5%s1/(h×l1).

Embodiment III:

the embodiment of the application provides a transformer, which comprises the three-dimensional wound core.

The content of the three-dimensional wound core is described in the first embodiment, and in this embodiment, the description of the content of the three-dimensional wound core is not repeated.

The above embodiments are only for illustrating the technical solution of the present application, and not for limiting the same; although the application has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims (10)

1. The three-dimensional wound iron core is characterized by comprising three iron core single frames, wherein each iron core single frame comprises a material belt and two adjacent soft magnetic materials, each iron core single frame comprises an iron core column part formed by winding the material belt, wherein the iron core column parts are arranged up and down, and the three iron core single frames are connected in a winding way through a tightening belt, so that a three-dimensional wound iron core with a regular triangle three-dimensional cross section is formed;

One soft magnetic material is placed at the soft iron yoke part in the interval multi-layer material belt of each iron core single frame, and two adjacent soft magnetic materials are distributed in the interval multi-layer material belt.

2. The three-dimensional wound core according to claim 1, wherein the material strip is made of a silicon steel material or an amorphous alloy material, and the soft magnetic material is a silicon steel material or an amorphous alloy material.

3. The three-dimensional wound core according to claim 1, wherein two adjacent layers of the material tapes are staggered in the width direction, and the widths of the material tapes gradually decrease from the middle to the two ends so that one side of the core single frame forms a plane and the other side of the core single frame forms an arc surface.

4. A solid wound core according to claim 3, wherein the angle between the plane and the strip is 60 °.

5. The solid wound core according to claim 1, wherein lengths of two adjacent pieces of the soft magnetic material gradually increase in order in a direction away from a center of the ribbon, and widths of two adjacent pieces of the soft magnetic material gradually decrease from the middle toward both ends so that the soft magnetic material corresponds to the width of the ribbon.

6. A method for manufacturing a three-dimensional wound core, applied to the three-dimensional wound core according to any one of claims 1 to 5, comprising the steps of:

acquiring magnetic density parameter and sectional area increasing data of the three-dimensional wound iron core, and processing the three-dimensional wound iron core into a plurality of material strips with widths gradually reduced from the middle to two ends by adopting silicon steel materials or amorphous alloy materials;

Determining the quantity of the soft magnetic materials according to the magnetic density parameters and the sectional area increasing data, and calculating the winding layer number of the soft magnetic materials placed on the material belt according to the sectional area increasing data;

One end of the material belt is fixed on a core mold, and the core mold is driven to rotate so as to drive the material belt to wind along the circumferential direction of the core mold; when the number of winding layers reaches the number of winding layers, placing a piece of soft magnetic material at the position of the iron yoke until the number of soft magnetic materials is completely placed, and winding the material strip according to the number of winding layers to obtain an iron core single frame;

And winding and connecting the three iron core single frames with the same structure on the iron core column parts of the iron core single frames through tightening belts so as to form the three-dimensional wound iron core with the regular-triangle three-dimensional cross section.

7. The method of manufacturing a three-dimensional wound core according to claim 6, comprising: when the mandrel is driven to rotate so as to drive the material belt to wind along the circumferential direction of the mandrel, one side of the material belt is abutted through the limiting piece, so that the material belt moves along the width direction of the material belt, and two adjacent layers of material belts are distributed in a staggered mode.

8. The method of manufacturing a three-dimensional wound core according to claim 6, wherein calculating the number of winding layers of the soft magnetic material placed on the tape based on the sectional area increase data comprises: the inverse of the cross-sectional area increase data is used as the number of winding layers of the soft magnetic material placed on the material belt.

9. The method of manufacturing a solid wound core according to claim 6, wherein the flux density parameter includes a yoke flux density, a yoke flux density value, and a soft magnetic material specification size of the solid wound core, and determining the amount of the soft magnetic material based on the flux density parameter and the sectional area increase data includes:

determining the iron yoke increasing area multiple of the three-dimensional wound iron core according to the ratio of the iron yoke magnetic density to the iron yoke magnetic density value;

and determining the quantity of the soft magnetic materials according to the iron yoke increase area multiple, the soft magnetic material specification size and the sectional area increase data.

10. A transformer comprising a solid wound core as claimed in any one of claims 1 to 5.