CN1308764A - 高叠层系数非晶态金属带及变压器铁心 - Google Patents

高叠层系数非晶态金属带及变压器铁心 Download PDF

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CN1308764A
CN1308764A CN99808439A CN99808439A CN1308764A CN 1308764 A CN1308764 A CN 1308764A CN 99808439 A CN99808439 A CN 99808439A CN 99808439 A CN99808439 A CN 99808439A CN 1308764 A CN1308764 A CN 1308764A
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amorphous metal
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CN1175436C (zh
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N·德克里斯托法罗
小R·L·布耶
D·A·恩戈
M·L·布里格斯
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Honeywell International Inc
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Abstract

本发明涉及高叠层系数的非晶态金属变压器铁心,还涉及构造高叠层系数非晶态金属变压器铁心的方法。该方法使用高分层系数非晶态金属带(术语分层系数通常用来表示带的平滑性和均匀性,而术语叠层系数用由带制造的铁心);即,具有在整个带宽上测量到的极平滑表面和极均匀厚度的非晶态金属带。通过卷绕或叠层操作,可以把高叠层系数非晶态金属带有效地组装成各种紧密形状的变压器铁心。然后把变压器铁心夹紧以便进一步缩小总尺寸,并且将其退火以便释放剩余机械应力以及产生所要求的磁性异向,而不损害最终磁性。

Description

高叠层系数非晶态金属带及变压器铁心
发明领域
本发明涉及高叠层系数非晶态金属变压器铁心，还涉及构造高叠层系数非晶态金属变压器铁心的方法。此方法使用高分层系数非晶态金属带(术语分层系数通常用来表示带的平滑性和均匀性，而术语叠层系数适用于由带制造的铁心)；即，具有在整个带宽上测量的极平滑表面和极均匀厚度的非晶态金属带。通过卷绕或层叠操作，高叠层系数非晶态金属带可以有效地组装成紧密的变压器铁心。然后夹紧变压器铁心，以进一步缩小总尺寸，并退火来释放剩余机械应力和产生所要求的磁性异向，而不破坏最终磁性。
与传统的非晶态金属变压器铁心相比，高叠层系数非晶态金属变压器铁心不仅铁心结构尺寸较小，而且还将保持相同的铁心净面积。铁心结构越小导致非晶态金属变压器铁心也越小，这又为减小变压器其他组件的尺寸或数量做好准备。例如，高叠层系数非晶态金属变压器将用较小的线圈绕组，还将用较小的金属外壳封装，并且，如果用于充液变压器，还将填充少量的油。这些因素都有助于降低非晶态金属变压器成本。
现有技术说明
非晶态金属变压器铁心可通过把单层非晶态金属带卷绕成环状来制造，或者通过把由多层非晶态金属带组成的组合件卷绕成环状来制造。然后沿径向线将该环切开，只产生一个接口。此环可在接口处打开，以便适应设置初级和次级线圈的需要，然后将该环闭合还原成初始环形状。
其它制造非晶态金属变压器铁心的方法是把单层非晶态带切割成设定长度，或者把包括多层非晶态带的组件切割成设定长度。然后这些切割的非晶态金属带绕心轴卷绕，或被层叠并绕心轴卷绕来形成紧密卷绕的铁心形状。各个长度的非晶态金属带这样缠绕在心轴上，使得切割端形成在铁心的定位区域对齐的一系列分布接口。通过分离分布接口，该铁心可以打开，以便适应设置初级和次级线圈的需要，然后将铁心闭合，以便重新形成初始的缠绕铁心形状。
美国专利4,734,975；5,261,152以及5,329,270公开了由几组非晶态金属带构造的非晶态金属变压器铁心，把非晶态金属带切割成预定长度并绕心轴缠绕以便形成分布接口铁心。在此通过引用这些专利的关于如何生产非晶态金属变压器铁心的讲授而将其包含在本文中。
利用传统的非晶态金属带、以这些方式制造的铁心，被限制在叠层系数大约等于或小于86％。因此，具有这些限制的铁心结构比传统的硅钢变压器大得多，制造变压器要使用更多的非晶态金属，更多的导体(铜或铝)作为初级和次级线圈，用更多的钢来做金属壳体，并且，如果使用充液变压器，用更多的油填充金属壳体。所有这些因素导致变压器生产中使用材料和变压器成本增加。生产成本损失20％-50％(或更多)。
此外，增加变压器尺寸在空间有限的很多部位和应用场合是不希望的。成本和尺寸损失限制了非晶态金属变压器的使用数量、因此也限制了其市场规模。
发明概述
具有由ASTM A 900-91确定的约为0.80-0.86的分层系数的非晶态金属带已经大批量生产。在美国专利4,142,571中阐明，这种带靠单一滚轮、单一喷嘴缝隙方法来生产。美国专利4,865,644和5,301,742讲授，通过使用带有多个位置相邻近的缝隙的喷嘴，非晶态合金带空间系数(分层系数)可达到约0.85-0.95之间，但是按传统方法加工的非晶态合金带分层系数限制在约0.75-0.85之间。
本发明的非晶态金属带靠单一滚轮、单一缝隙方法来铸造，但出乎意料的是显示出分层系数大于0.86(术语分层系数通常用来表示带的平滑性和均匀性，术语叠层系数用于由带构成的铁心)。确实，已经获得高达92％的分层系数。这是通过形成在整个带宽测量到的极平滑的带表面和极均匀带厚度来达到的。
通过仔细控制喷嘴缝隙几何图形来保持整个带宽上的极均匀的厚度。通过确保喷嘴缝隙基本上保持矩形来保持带中心到带边缘的厚度均匀性。为了控制热机械形变，这样选择喷嘴材料、设计和夹具，使得沿其长度方向缝隙宽度变化不超过约5％。虽然有一种尺寸完全固定不变的喷嘴是人们所希望的，但是以这样的方式夹紧喷嘴以便使形变最小的方法被认为提供了对喷嘴尺寸的辅助控制。
为了保持带的一边到带的另一边厚度极均匀，控制喷嘴和轮子之间的间距、使得从缝隙的一端到另一端的变化量小于约5％也是必要的。本发明使用以下装置：它根据浇铸带边缘到边缘的测量结果，调整喷嘴相对于轮子的位置，以便使边缘到边缘的厚度变化最小。
要保持带表面极平滑就要求喷嘴表面和轮子表面平滑。实现喷嘴表面平滑的方法如下：对在浇铸过程中与熔融金属接触的喷嘴缝隙表面进行机加工，达到表面粗糙度Ra约小于5微米。为了在浇铸过程中保证喷嘴表面光滑，使用惰性气体或还原气体的保护气氛，以便将会降低初始表面光洁度的喷嘴与熔融金属之间的作用减至最小。此外保护气氛的使用将使喷嘴上积聚的增加浇铸带粗糙程度的熔渣微粒减到最少。靠不断施加其平均粒度小于约60微米的极精细粒度研磨剂的磨料，来保持圆形铸锭轮表面平滑。
高分层系数带允许构造本发明的高叠层系数的变压器铁心。具有高分层系数非晶态金属带的变压器铁心可利用本专业的技术人员已知的传统的铁心构造技术来制造。然后，把用高分层系数带制造的铁心夹紧，以便进一步缩小总尺寸，并退火来释放剩余机械应力以及产生所要求的磁性异向，而不损害最终磁性。可以设计和生产本发明的叠层系数等于或大于86％的变压器铁心。
实施例
实施例1
以美国专利4,142,571讲授的方式并且利用以下各特定参量来浇铸Fe86B11Si9非晶态金属带。a)喷嘴和喷嘴夹具
喷嘴体由粘土-锆石制作。将喷嘴体整体地增强以使浇铸非晶态金属时热机械形变最小。在喷嘴体中加工宽170毫米，厚0.5毫米(+/-0.08毫米)的缝隙。这样进行该机加工，使得缝隙表面显示的表面粗糙度Ra小于5微米。喷嘴体设置在外部增强的框架内以使浇铸非晶态金属时热机械膨胀最小b)喷嘴装配和控制
如此来定位喷嘴，使得喷嘴和圆形铸锭机(casting wheel)之间的间距变化小于5％。虽然在浇铸非晶态金属时，该间距很难直接测量和控制，但实时测量实际带厚度提供了喷嘴到轮子间距的代表。这些测量靠使用X射线线规或电容探头来完成。不断调整喷嘴到轮子的间距以保持其变化小于5％。c)圆形铸锭轮装配和控制
研磨和抛光圆形铸锭轮使其表面达到粗糙度Ra小于5微米。为了使熔融金属和圆形铸锭轮之间的反应最小，喷嘴缝隙周围充满还原气体。为了保持贺形铸锭轮表面平滑，在浇铸非晶态金属时，不断把磨料加到轮的表面。磨料粒度小于150微米。磨料粘附在刷子的纤维上或放在纸的表面上。生产了具有如下的分层系数的宽170mm、厚0.023mm的非晶态金属带。
RUN  1卷 2卷 3卷 4卷
 B17237  0.876  0.915  0.909  0.905
 B17402  0.881  0.880  0.869  0.878
 B18376  0.876  0.902  0.894  0.897
实施例2.
根据实施例1制造的分层系数在0.873-0.876范围的非晶态金属带被用来构造非晶态金属变压器铁心。可用美国专利4,734,975；5,261,152和5,329,270中阐明的技术来构造变压器铁心。铁心叠层系数作如下设定。在此使用的术语叠层系数定义为铁心引脚净横截面积和铁心总的横截面积之比，计算方法为：
叠层系数＝M/(1/2(Li+Lo)×t×W×ρ)其中M＝铁心重量Li＝叠片内部长度Lo＝叠片外部长度t＝测量的引脚厚度W＝带宽ρ＝带密度
铁心编号 叠层系数
HF003008  0.903
HF003009  0.903
HF003013  0.900
HF003014  0.905
HF003015  0.904
HF003016  0.904

Claims (8)

1.一种具有用ASTM A 900-91测量的等于或大于86％分层系数的非晶态金属带。
2.权利要求1的非晶态金属带，其特征在于具有等于或大于90％的分层系数。
3.权利要求1的非晶态金属带，其生产步骤为：
a)通过具有单一缝隙的喷嘴浇铸熔融金属；
b)把所述熔融金属浇铸在单一的滚轮上，以便形成带状型材；以及
c)以105K/s冷却速率固化所述带状型材，以便形成所述非晶态金属带。
4.权利要求2的非晶态金属带，其生产步骤为：
a)通过具有单一缝隙的喷嘴浇铸熔融金属；
b)把所述熔融金属浇铸在单一的滚轮上，以便形成带状型材；以及
c)以105K/s冷却速率固化所述带状型材，以便形成所述非晶态金属带。
5.一种非晶态金属变压器铁心，它显示等于或大于86％的叠层系数。
6.一种非晶态金属变压器铁心，它显示等于或大于90％的叠层系数。
7.一种变压器铁心，它包括具有等于或大于86％的分层系数的非晶态金属带。
8.一种变压器铁心，它包括具有等于或大于90％的分层系数的非晶态金属带。
CNB998084395A 1998-05-13 1999-05-13 高叠层系数非晶态金属带及变压器铁心 Expired - Lifetime CN1175436C (zh)

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CN112599347A (zh) * 2020-11-26 2021-04-02 天长市盛泰磁电科技有限公司 一种磁芯分层机

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CN112599347A (zh) * 2020-11-26 2021-04-02 天长市盛泰磁电科技有限公司 一种磁芯分层机
CN112599347B (zh) * 2020-11-26 2022-04-05 天长市盛泰磁电科技有限公司 一种磁芯分层机

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ATE313146T1 (de) 2005-12-15
JP2010184298A (ja) 2010-08-26
JP5165820B2 (ja) 2013-03-21
EP1078377A1 (en) 2001-02-28
KR100637916B1 (ko) 2006-10-24
CA2333287A1 (en) 1999-11-18
JP2004500697A (ja) 2004-01-08
DE69928923D1 (de) 2006-01-19
DE69928923T2 (de) 2006-08-17
ES2255268T3 (es) 2006-06-16
CN1175436C (zh) 2004-11-10
EP1078377B1 (en) 2005-12-14
AU3902999A (en) 1999-11-29
HK1039680B (zh) 2005-08-05
KR20010043569A (ko) 2001-05-25

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