EP2395522B1 - Verfahren zur Herstellung von Transformatorkernen, Verfahren zur Herstellung eines Transformators mit einem solchen Kern - Google Patents

Verfahren zur Herstellung von Transformatorkernen, Verfahren zur Herstellung eines Transformators mit einem solchen Kern Download PDF

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Publication number
EP2395522B1
EP2395522B1 EP10005876.7A EP10005876A EP2395522B1 EP 2395522 B1 EP2395522 B1 EP 2395522B1 EP 10005876 A EP10005876 A EP 10005876A EP 2395522 B1 EP2395522 B1 EP 2395522B1
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EP
European Patent Office
Prior art keywords
core
cutting
laser
transformer
cut
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP10005876.7A
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English (en)
French (fr)
Other versions
EP2395522A1 (de
Inventor
Benjamin Weber
Jasmin Smajic
Martin Dr. rer. nat. Carlen
Lise Dr. Donzel
Stephane Dr. Schaal
Thorsten Steinmetz
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ABB Schweiz AG
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ABB Schweiz AG
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Priority to EP10005876.7A priority Critical patent/EP2395522B1/de
Priority to PCT/EP2011/002349 priority patent/WO2011154076A1/en
Publication of EP2395522A1 publication Critical patent/EP2395522A1/de
Application granted granted Critical
Publication of EP2395522B1 publication Critical patent/EP2395522B1/de
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0213—Manufacturing of magnetic circuits made from strip(s) or ribbon(s)
    • H01F41/0226—Manufacturing of magnetic circuits made from strip(s) or ribbon(s) from amorphous ribbons
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/04—Cores, Yokes, or armatures made from strips or ribbons

Definitions

  • the invention relates to a method for manufacture of a transformer core made of ferromagnetic material, such as amorphous metal or silicon iron, which is provided as a single ribbon layer or as multiple ribbon layers wound on a winding mandrel.
  • ferromagnetic material such as amorphous metal or silicon iron
  • a major component of a transformer is its core with the purpose of guiding the magnetic flux whereas the core usually consists of laminated steel laminations.
  • Transformers for use at power typically have cores made of high permeability silicon steel which has a permeability many times that of free space, and the core thus serves to greatly reduce the magnetizing current, and confine the flux to a path which closely couples the windings.
  • Each lamination is insulated from its neighbors by a thin non-conducting layer of insulation.
  • the transformer core causes energy losses due to hysteresis and eddy currents.
  • amorphous metal typically FeBSi alloy
  • Si-steel Si-steel
  • the manufacturing of the cores is labor intensive and costly. This ID presents an alternative manufacturing method which allows simplifying several of the manufacturing steps
  • a method of constructing a transformer having an amorphous steel core having a coil about a leg of the core wherein the core leg is formed to a cross section that more closely conforms to the configuration of the coil window of the coil that surrounds the core leg.
  • the core leg is formed of superposed strips of amorphous steel which are somewhat thicker in their central region than at their edges and which are squeezed together at their edges to form the conformal cross-section.
  • a transformer core is made by winding a strip of ferromagnetic material, such as amorphous metal or silicon iron, on a winding mandrel to form a first annulus and cutting once through this annulus to create a plurality of individual laminations which are then assembled in packets about a nesting mandrel of a smaller diameter than the winding mandrel to form a second annulus.
  • Each packet consists of a predetermined number of groups of laminations, with the ends of each lamination group lapping each other to form a lap joint.
  • US 4 709 471 A discloses a method of constructing a transformer having a magnetic core by winding a strip of amorphous metal to form a plurality of laminations and cutting all the laminations using laser cutting means.
  • each packet is arranged in staggered positions to create a repeating step-lap joint pattern confined within a predetermined joint region.
  • the invention provides in claim 1, an alternative manufacturing method which allows simplifying several of the manufacturing steps.
  • the claimed method is characterized by the following steps
  • laser cutting instead of mechanical cutting has been provided as well as the continuous winding of the ribbons of ferromagnetic material, such as amorphous metal or silicon iron, forming the core until the final shape has been achieved.
  • ferromagnetic material such as amorphous metal or silicon iron
  • the laser cutting device and the spooling mechanism may be manually operated, but preferably it is partly or fully automated which is advantageous for the handling with the spooling of the ribbon.
  • laser cutting is more reliable and more precise as to the trimming of the borders than the customary mechanical cutting, especially with regard to the surface quality of the respective cut line.
  • a further preferred provision is characterized in that the winding axis has a horizontal or vertical or any other direction.
  • either the core or the laser beam are being displaced, or the direction of the laser beam is being adjusted.
  • the laser beam is being displaced by one or several mirrors.
  • the single ribbon layers or bundles of layers can be wound at a time, i.e. simultaneously.
  • the winding process of the ribbon is being executed fully or partly by automatic equipment, though likewise manually operated equipment is applicable.
  • the winding axis can be provided to have horizontal or vertical direction or any other direction.
  • Evans cores which finally comprise three core legs, the outer loop can directly be wound on the two inner loops.
  • strips of different material can locally be inserted into the winding.
  • These inserts can be introduced between each ribbon layer respectively between any bundle of layers.
  • the purpose of these inserts is to limit the depth of the cuts.
  • the laser is positioned below the core respectively the loop for cutting.
  • the ribbon layers are enabled to open up (unlace) by gravitational force.
  • the inserts can be displaced, and thus allowing a stepped butt configuration. Consequently the inserts can be made of amorphous metal, Si-steel, other metal foils or polymeric foils, whereas a preferred polymeric foil is made from PTFE.
  • the cuts are effected at the position of the inserts within the core. If any inserts are present in the core, such inserts are removed after effecting the cuts.
  • the individual layers advantageously weld together at the cut which simplifies the handling during re-lacing.
  • the wound core body is annealed for at least 1 ⁇ 2 hour at about 350°C in order to equalize the structure of the amorphous metal.
  • the annealing takes place when the core body is complete i.e. that the loop is still closed and not yet unlaced, i.e. opened.
  • the cutting of the core body is effected before the annealing procedure has been initiated. Due to laser cutting which is an essential feature of the invention it does not matter when the annealing procedure of the core takes place i.e. before or after cutting the loop.
  • the core is being annealed when it is unlaced in order to give access to the core legs which are formed by the long sides of the core.
  • the core legs including the lower part of the core which connects the core legs are coated with resin or a different polymeric material which provides as well mechanical stability as protection against mechanical wear.
  • the coating of the core legs is effected after annealing the core, i.e. after it has been annealed, and before it is unlaced, i.e. opened, in order to make then the core legs accessible for receiving the respective transformer coils.
  • the core After re-lacing the core i.e. closing the core the rest of the core is coated, too. At this stage, i.e. when the coating has been cured the core is ready for use as a transformer core.
  • an object of the invention is to disclose a new method for manufacture of a transformer using such a core as described before.
  • a method for manufacture of a transformer having a core made of amorphous metal as it has been illustrated before is characterized by the following steps
  • transformers having a core of amorphous metal With transformers having a core of amorphous metal the core and the coils are manufactured separately and then assembled. This requires that the core is opened for inserting the coils.
  • the core is provided for an annealing procedure which is executed after removing of the mandrel which is provided for manufacture of the core.
  • the transformer core which consists of a plurality of thin layers of foil to prevent the core from breaking down and losing its shape.
  • other devices are being provided to maintain the shape of the core such as supports, molds or clamps.
  • Fig. 1a to 1d four stages of manufacture of a core 10 for a transformer according to the state of the art whereas the core 10 of is made from single stacked layers of amorphous metal. All these figures are shown in lateral view.
  • Fig. 1 a shows a 1 st stage of the manufacturing process when the core has been finished.
  • This process is executed by cutting of the amorphous ribbon to the appropriate length.
  • the cutting is done by a metal shears, which is a Guillotine-like device.
  • a bundle or a number of layers is cut simultaneously.
  • the outer layers of a core need to be longer than the inner layers. This requires permanent adjustments of the cutting length
  • Fig. 1 b shows a 2 nd stage when the core has been opened respectively when the ribbons have been unlaced for forming core legs where coils are received. This unlacing of the single layers is usually done manually by means of mechanical equipment.
  • Fig. 1 c a 3 rd stage of the conventional method has been shown where the core legs 12 receive the provided coils.
  • Fig. 2a shows a rectangular core loop 16 manufactured according to the invention and being formed by a nearly endless i.e. continuously wound ribbon (not shown in detail) of amorphous metal being supported by core supports 18 which keep the core in shape.
  • the positioning of the core 16 has been provided in that way that the cut for unlacing the ribbons and thus for opening the core 16 is effected from below.
  • a laser 22 is being provided whereas the laser provided for the cut is directing its beam 24 to the ribbons from below of the core 16 accordingly. Additionally locally, e.g. between each layer of the ribbons, some inserts 21 are being introduced in order to limit the depths of the cuts effected by the laser.
  • the core 16 according to Fig. 2b is being supported by a mandrel 26 which is to be removed when the cut of the ribbons has been finished in order to allow the core legs 20 of the core 16 receive the respective coils (not shown)
  • FIG. 3 a similar arrangement as shown in Fig. 2a is being displayed but here with an Evans core which comprises two neighboring cores being enveloped by a third core which is clasping the two cores commonly.
  • FIG. 4a a similar arrangement is shown as already in Fig. 2a but here with a trapezoidal core loop 28 on a trapezoidal mandrel 30 whereas the rest of the arrangement is the same as with that shown in Fig. 2a .
  • a laser 22 is positioned below of the core 28 and its beam 24 is directed to the lower front of the core 28 where the inserts 21 have been introduced between the layers of the ribbons as illustrated before.
  • Fig. 4b a staggered step-lap rectangular core loop 28 after re-lacing is shown.
  • the formerly cut parts of the core which corresponds to the base side in Fig. 4a i.e. the longer of both short sides, have been re-laced i.e. reunited and finally the upper and the lower short sides have the same length thus the core is rectangular.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)

Claims (13)

  1. Verfahren zur Herstellung eines aus einem ferromagnetischen Material wie etwa amorphem Metall oder Siliziumeisen hergestellten Transformatorkerns, der als eine einzelne Bandschicht oder als mehrere Bandschichten vorgesehen ist,
    wobei
    a) die einzelnen Bandschichten oder das Bündel von Bandschichten aus ferromagnetischem Material wie etwa amorphem Metall oder Siliziumeisen kontinuierlich in Schleifen gewickelt werden, wohingegen die Form der Kernschleifen mit Hilfe eines direkt in seine Endgestalt auszubildenden entsprechenden Dorns bewirkt wird;
    b) die einzelnen oder mehreren Bandschichten der Schleifen so geschnitten werden, dass
    - ein Laser für das Schneiden verwendet wird, was ein schnelles und präzises Schneiden der Bänder gestattet, und dass
    - alle Bänder der Schleifen an zumindest einer Position entlang des Umfangs jeder Bandschicht geschnitten werden,
    dadurch gekennzeichnet, dass
    das Positionieren des Kerns/der Schleife, um sie auf die entsprechende Länge zu schneiden, der Laser darunter platziert wird, damit sich die Bandschichten durch Schwerkraft öffnen (entschachteln) können.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der Dorn entfernt wird und der Kern vorübergehend fixiert wird, um seine Gestalt mit Hilfe einer Form oder irgendeiner angemessenen Stütze zu halten.
  3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass der Kern getempert wird, wohingegen die Schleife geschlossen wird.
  4. Verfahren nach einem der vorhergehenden Ansprüche, wobei der Kern teilweise oder vollständig mit Harz oder einem anderen polymeren Material beschichtet wird, um seine Struktur mechanisch zu stabilisieren.
  5. Verfahren nach mindestens einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass während des Wickelprozesses Streifen aus unterschiedlichem Material lokal in die Wicklung eingesetzt werden können, wohingegen die Schnitte an der Position der Einsätze vorgenommen werden.
  6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, dass die Einsätze nach jeder Bandschicht oder nach einem Bündel von Schichten eingeführt werden, um die Tiefe der Schnitte zu begrenzen.
  7. Verfahren nach Anspruch 5 oder 6, umfassend dadurch gekennzeichnet, dass die Einsätze versetzt werden, was eine Step-Butt-Konfiguration gestattet.
  8. Verfahren nach mindestens einem der Ansprüche 5 bis 7, dadurch gekennzeichnet, dass die Einsätze aus amorphem Metall, Si-Stahl, anderen Metallfolien oder polymeren Folien, zum Beispiel aus PTFE hergestellt, bestehen.
  9. Verfahren nach mindestens einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Wickelachse eine horizontale oder vertikale oder irgendeine andere Richtung besitzt.
  10. Verfahren nach mindestens einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass im Fall von Evans-Kernen die äußere Schleife direkt auf die beiden inneren Schleifen gewickelt werden kann.
  11. Verfahren nach mindestens einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass zum Versetzen der Position der Schnitte entweder der Kern oder der Laser versetzt wird, die Richtung verstellt wird oder der Laserstrahl durch mindestens einen Spiegel versetzt wird.
  12. Verfahren nach mindestens einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass andere als gerade Schnitte vorgenommen werden, z.B. ein wellenförmiger Schnitt, um den Magnetfluss zu verbessern und Verluste und Erregungsstrom zu reduzieren.
  13. Verfahren zur Herstellung eines Transformators mit einem aus amorphem Metall oder einem anderen ferromagnetischen Material wie Siliziumstahl hergestellten Kern gemäß mindestens einem der vorhergehenden Ansprüche, gekennzeichnet durch die folgenden Schritte
    a) nachdem die Wicklung der aus ferromagnetischem Material wie etwa amorphem Metall oder Siliziumeisen bestehenden Bänder fertiggestellt worden ist, wird der Kern mit Stützen versehen, um die Gestalt des Kerns beizubehalten, und eine Seite der Kernschleife wird mit Hilfe von Laserschneiden geschnitten, wohingegen vor oder nach dem Schneiden des Kerns eine Temperungsprozedur stattfindet;
    b) nach der Temperungsprozedur werden die Schnittenden der jeweiligen Kernschleife hochgebogen, so dass die Kernschenkel zugänglich sind;
    c) dann wird zumindest der untere Teil des die Kernschenkel und seinen Verbindungsteil umfassenden Kerns mit Harz oder einem anderen polymeren Material beschichtet, um ihn mechanisch stabil zu machen,
    d) auf mindestens einem Kernschenkel wird zumindest eine Transformatorspule verschoben und
    e) dann wird der geöffnete Kern wieder verschachtelt und der noch nicht beschichtete Teil des Kerns wird beschichtet.
EP10005876.7A 2010-06-08 2010-06-08 Verfahren zur Herstellung von Transformatorkernen, Verfahren zur Herstellung eines Transformators mit einem solchen Kern Not-in-force EP2395522B1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP10005876.7A EP2395522B1 (de) 2010-06-08 2010-06-08 Verfahren zur Herstellung von Transformatorkernen, Verfahren zur Herstellung eines Transformators mit einem solchen Kern
PCT/EP2011/002349 WO2011154076A1 (en) 2010-06-08 2011-05-12 Method for manufacture of transformer cores, a method for manufacture of a transformer having such core and a transformer manufactured according to this method

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP10005876.7A EP2395522B1 (de) 2010-06-08 2010-06-08 Verfahren zur Herstellung von Transformatorkernen, Verfahren zur Herstellung eines Transformators mit einem solchen Kern

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Publication Number Publication Date
EP2395522A1 EP2395522A1 (de) 2011-12-14
EP2395522B1 true EP2395522B1 (de) 2017-08-09

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EP10005876.7A Not-in-force EP2395522B1 (de) 2010-06-08 2010-06-08 Verfahren zur Herstellung von Transformatorkernen, Verfahren zur Herstellung eines Transformators mit einem solchen Kern

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WO (1) WO2011154076A1 (de)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6583176B2 (ja) * 2016-07-25 2019-10-02 株式会社村田製作所 粉塵対策装置
CN107316739A (zh) * 2017-06-19 2017-11-03 广东紫光电气有限公司 一种开口折叠式变压器铁芯制备方法

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4814736A (en) 1986-03-13 1989-03-21 General Electric Company Wound transformer core
US4709471A (en) * 1986-08-15 1987-12-01 Westinghouse Electric Corp. Method of making a magnetic core
US4847987A (en) 1988-08-29 1989-07-18 General Electric Company Method of making a core and coil assembly
US4972168A (en) * 1989-01-03 1990-11-20 Abb Power T & D Company, Inc. Transformers and cores for transformers
DE19951180A1 (de) * 1999-10-23 2001-04-26 Abb Research Ltd Verfahren zur Herstellung eines Bandes

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EP2395522A1 (de) 2011-12-14

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