EP3035351B1 - Verfahren zur herstellung eines amorphen magnetkerns und amorpher magnetkern - Google Patents

Verfahren zur herstellung eines amorphen magnetkerns und amorpher magnetkern Download PDF

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Publication number
EP3035351B1
EP3035351B1 EP14460108.5A EP14460108A EP3035351B1 EP 3035351 B1 EP3035351 B1 EP 3035351B1 EP 14460108 A EP14460108 A EP 14460108A EP 3035351 B1 EP3035351 B1 EP 3035351B1
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Prior art keywords
core
layers
lamination layers
lamination
binder
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French (fr)
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EP3035351A1 (de
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Grzegorz Kmita
Robert Sekula
Andrzej RYBAK
Michal Kozupa
Pawel Klys
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ABB Schweiz AG
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ABB Schweiz AG
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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

Definitions

  • the invention relates in general to manufacturing of an improved amorphous metal magnetic core for electrical inductive apparatus such as transformers and reactors.
  • Transformer cores are commonly manufactured using silicon steel laminations as the magnetic core material. Such cores,are rigid, self-supporting and are not very stress sensitive. Alternatively, magnetic cores may be manufactured of amorphous metal lamination layers. Currently, the amorphous metal-based transformer cores are more and more often used in the market. They advantageously offer a very, low level of the no-load losses, called also core losses, which is beneficial for their use in the power grid.
  • Amorphous metal-based transformer cores has, however, some drawbacks which are related to the manufacturing process, their handling and assembly in transformers as well as to the increased average level of the noise emitted by a transformer unit, which results from the increased magnetostriction.
  • the difficulties with both handling and assembling is caused by a limited resistance to buckling the core and lack of a self-supportive functionality. This produces issues with stabilization of the amorphous cores and a need for additional supporting frames needed in the design. Improper handling can additionally lead to ribbon deformation or ribbon sliding and induces mechanical stresses, which results in loss of structural integrity and degradation of magnetic properties.
  • amorphous cores have been encapsulated or at least part of amorphous metal lamination layers should be coated on the edges with a low-stress and low-viscosity coating material.
  • the method for coating the edges of a magnetic core containing strips of amorphous metal is known from patent description US 6,413,351 .
  • the lamination layers are coated on the edges with a low-stress, low-viscosity coating material which, when cured, becomes sufficiently rigid to support the lamination layers of amorphous material.
  • the coating material can be applied to the entire edge surface of both sides of the core or only to selected portions of the edges on other side. In either instance, the coating material is applied in a manner that allows built-in stresses to relax out before all coating material is fully cured, however the patent is silent about the noise decreasing level of the core emitted during the work of the transformer with such a core.
  • a magnetic core having reduced audible noise and a method of making the amorphous alloy-based magnetic core emanating low audible noise is known from patent US 8,427,272 .
  • the method includes: placing the core with multiple layers of high strength tape on the core legs, wherein the tapes have a high tensile strength, high dielectric strength and high service temperature, resulting in reduced level of audible noise.
  • the reduced level of audible noise is 6-10 dB less when compared with a same -size core that has been coated with resin instead.
  • the method according to this solution is rather labour-consuming. Wrapping the legs of the transformer by using the tapes increases the number of steps during the manufacture of the core.
  • the method can have certain limitations in application for bigger cores where the use of high-strength tapes is questionable, since both the dimensions and weight of the core may lead eventually to its buckling despite presence of the tape.
  • the essence of a method of manufacturing an amorphous magnetic core wherein the method comprises assembling a plurality of lamination layers made of amorphous metal strips to designing a wound core shape or a stacked core shape wherein the wound core shape has two parallel faces formed by edges of the lamination layers and has means for constraining the shape of the core during the manufacturing, whereas the stacked core shape, has side faces formed by edges of the lamination layers, is that the method further comprises: a step of step of introducing between the neighboring lamination layers of the core an organometallic binder for receiving a number of film layers, wherein the thermal expansion coefficient of the film layers is lower than the a thermal expansion coefficient of lamination layers.
  • Each film layer is disposed through the whole cross-section of the core, perpendicular to the both faces of the wound core or to the all side faces of the stacked core.
  • Next step of binding together the lamination layers with the film layers is performed by annealing the core in a magnetic field having value above 800A/m.
  • the lamination layers bonded together with the film layers for reducing audible noise when the core is under operating condition.
  • a liquid sol is used as the organometallic binder.
  • the liquid sol has a viscosity from 0.1 cps (0,1 mPa ⁇ s) to 50 cps (50 mPa ⁇ s).
  • the organometallic binder Preferably as the organometallic binder, a single organosillicon sol or a mixture of the various organosillicon sols are used.
  • the step of introducing of the organometallic binder between the neighboring lamination layers of the core is performed by brushing at least one part of the face or the side faces of the core formed by edges of the lamination layers.
  • the step of introducing of the organometallic binder between the neighboring lamination layers of the core is performed by immersing in a liquid sol at least a part of the core.
  • the step of introducing of the organometallic binder between the neighboring lamination layers of the core is performed by spraying the organometallic binder on lamination layers before the step of assembling a plurality of lamination layers made of amorphous metal strips to designing a core shape.
  • the essence of an amorphous magnetic core structure having lamination layers made of amorphous metal strips and the film layers made of an organometallic binder, is that the film layers are placed between the eighboring lamination layers.
  • the thermal expansion coefficient of each of the film layers is lower than the thermal expansion coefficients of the neighboring lamination layers.
  • the structure formed by lamination layers bonded with film layers forms the core thereby reducing audible noise when the core is under operating condition.
  • each of the film layers is disposed in the space between the two neighboring lamination layers and the film layers is are in contact with the two opposite faces of each of the neighboring lamination layers.
  • the lamination layers have the thermal expansion coefficient near to 7,8x10 -6 [1/K].
  • a core having a structure according to claims 8-10 is used in an electrical apparatus.
  • An electrical apparatus according to claim 11 wherein the electrical apparatus is a power transformer or distribution transformer.
  • the improved amorphous magnetic core according to the invention is self-supporting structure, where mechanical stability is obtained.
  • the lamination layers in amorphous cores which usually tend to separate each other and to straighten themselves are formed to a desired shape and then bonded together in a form of a bulk component thanks to the unique organometallic binders with almost zeroed thermal expansion coefficients.
  • the organometallic binders is introduced between the lamination layers during manufacturing process, but before the thermomagnetic treatment process, which is annealing at the standard treatment temperature (normally 350-400°C) and in the presence of magnetic field (normally 800-1000A/m).
  • the organometallic binders used provide at the same time in the amorphous cores a specific tensile stress state condition in the laminations layers, decreasing the resulting noise level emitted by amorphous magnetic core during operation of the device with such core.
  • the improved magnetic core is consolidated with an organometallic binder, which bond together the lamination turns.
  • An improved method assures penetrating of the organometallic binder in a liquid sol form between the lamination turns, however, resulting properties of the solidified binder prevent from unwanted stress development in the core, which would increase its losses.
  • the present invention provides technology of the low no-load loss amorphous metal magnetic cores manufacturing which assures self-supporting functionality what as well as the decreased audible noise emission of an electrical device built based on a new and improved core.
  • a core 1 has two leg portions 2 and 4, and two yoke portions 3 and 5 which are formed from amorphous alloy strip lamination layers 6.
  • a distributed gap 7 is formed by staggered overlapping of the ends of the amorphous alloy strip lamination layers 6.
  • a very thin film layers 8 of organometallic binder is introduced for at least part of legs or yokes.
  • the lamination layers 6 and the film layers 8 form a structure of a core.
  • the edges of the lamination layers and the film layers define two parallel faces 9 of the core.
  • the core is supported from an external side by a band 10 of ferromagnetic material placed perpendicularly to the core faces.
  • the ferromagnetic material can be a silicon steel of 0.2-0.3 mm thickness and it is used to constrain the shape of the core, since the core tends to straighten and/or to open during manufacturing step when not constrained.
  • the film layers 8 are made of an organometallic material forming a organometallic binder 11, especially having a form of liquid sol.
  • a core 1' has two leg portions 2' and 4', and two yoke portions 3' and 5' which are formed from amorphous alloy strip lamination layers 6'. Between the two neighboring lamination layers 6' a very thin film layers 8' of organometallic binder is introduced for at least part of legs or yokes.
  • the lamination layers 6' and the film layers 8' form a structure of a core 1'.
  • the edges of the lamination layers and the film layers define side surfaces 9' of the core.
  • the film layers 8' are made of an organometallic material forming an organometallic binder 11, especially having a form of liquid sol.
  • the method according to the invention is realized in the following way.
  • First the process of assembling a plurality of lamination layers 6 made of amorphous metal strips to designing a core shape is performed in a known way. It can be performed either by winding of the lamination layers with a controlled tension in order to obtain the filling factor of the core above 80% or by stacking of the lamination layers with a controlled compression in order to obtain the filling factor of the core above 80%.
  • the step of introducing between the neighboring lamination layers 6 or 6' of the core 1 or 1', respectively, an organometallic binder 11 in a form of a low viscosity liquid sol is applied on the face(s) 9 of the core 1 or side surface(s) 9' of the core 1'.
  • the organometallic binder in a form of a liquid sol a can be applied with the use of a brush or equivalent technique. Such method is shown in fig.5 only for the first embodiment of the invention. It is understood that the similar method is used for the second embodiment of the invention, what is not presented in the drawing.
  • the organometallic binder penetrates easily in-between the neighboring lamination layers 6 or 6' filling all the gaps in the core structure forming a very thin film layers 8 or 8' of organometallic binder 11.
  • the bonding material adheres well to the lamination layers and is capable for penetrating through the core with substantial wicking between the core lamination layers. Accordingly, bonding materials in a liquid sol forms having a viscosity from 0.1 cps (0,1 mPa ⁇ s) to about 50 cps (50 mPa ⁇ s) are preferred.
  • the organometallic binder in a liquid sol form has a viscosity from 0.1 cps (0,1 mPa ⁇ s) to 10 cps (10 mPa ⁇ s).
  • T/D Triethoxymethylsilane
  • D Diethoxydimethylsilane
  • the organometallic binder also the sole organosilicon may be used.
  • the amount of the organometallic binder material in a liquid sol form applied must be sufficient to result in substantial wicking between the lamination layers of the core.
  • the bonding between the neighboring lamination layers 6 or 6' is obtained during standard thermomagnetic treatment of the cores at 350-400°C when the organometallic binder melts and then solidifies during cooling.
  • Complex hardening/solidification steps such as UV or chemical curing are not necessary to set the bonding materials of the present invention. Accordingly, the present invention provides an improved method for providing increased mechanical strength to amorphous alloy cores with substantially reduced risk of degradation of the mechanical properties thereof.
  • the other ways of the introducing of the organometallic binder 11 between the neighboring lamination layers 6 or 6' of the core 1 or 1' are performed after assembling of the core and next by immersing a part of a core 1 or 1' ( fig.6 ) or the whole core 1 or 1' ( fig.7 ) in a tank 12 filled with the organometallic binder 11 having a liquid sol form.
  • Such methods are shown in fig.6 and fig.7 only for the first embodiment of the invention. It is understood that the similar method is used for the second embodiment of the invention, what is not presented in the drawing.
  • the organometallic binder can be applied partly either on subsequent legs and yokes or on the whole core depending on the needs.
  • an organometallic binder 11 is applied during the assembling the designed shape of a core by e.g. spraying of each lamination layer 6 directly before winding/shaping of the core 1.
  • the organic binder may be a liquid sol or may have a form of small solid particles 11a, which after spraying on the surface of the layers 6 covered the all surface.
  • the core 1 may not be supported from en external side by a band of ferromagnetic material like in the previous embodiments.
  • the bonding between the neighboring lamination layers 6 is obtained during standard thermomagnetic treatment of the cores at 350-400°C when the organometallic binder melts and then solidifies during cooling.
  • an organometallic binder 11 is applied during the assembling the designed shape of a core by e.g. spraying of each lamination layer 6' directly before assembling/stacking of the core 1'.
  • the organometallic binder 11 may be a liquid sol or may have a form of small solid particles 11a, which after spraying on the surface of the layers 6' covered the all surface.
  • the bonding between the neighboring lamination layers 6' is obtained during standard thermomagnetic treatment of the cores at 350-400°C when the organometallic binder melts and then solidifies during cooling.
  • the organometallic binder after solidification is electrically isolative and a rigid component.
  • the organometallic binder between the amorphous metal lamination layers and following thermomagnetic treatment After application of the organometallic binder between the amorphous metal lamination layers and following thermomagnetic treatment, the high strength bulk amorphous metal magnetic core is produced and the high strength structure provides the necessary structural support to make the core self-supporting over the complete operating temperature range of the associated apparatus.
  • the organometallic binder bonds together the amorphous ribbons and having thermal expansion coefficient, CTE, lower than the CTE of amorphous metal lamination layers, which is around 7,8 x10 -6 [1/K], produces a preferable state of stress in the lamination layers, which enables the reduced audible noise emission without applying significant stresses to the core thus the increase in level of the core losses is avoided.
  • the organometallic binder adheres well to amorphous metal lamination layers after the solidification occurring during the thermomagnetic treatment, thus enables the composite core to handle mechanical stresses, and protects the core from stresses developed during coil winding, and it withstands thermal cycling stresses created in the operating environment.
  • the organometallic binders include components, which after solidification, are compatible with the usual transformer coolants or liquid dielectrics, such as mineral oil.
  • the organometallic binder is applied in a liquid sol form having viscosity from 0.1 cps to 50 cps (0,1 mPa.s to 50 mPa.s), which ensures complete penetration of the sol between the laminations of the amorphous magnetic core, including substantial wicking.
  • the binder in the form of a liquid sol is introduced between the lamination layers of the core before the thermomagnetic treatment step without the need for molds, using immersion technique, or a simple application with e.g. brushing or equivalent, or spraying techniques.
  • the organometallic binder in the form of a liquid sol is suitable for a standard heat treatment together with the core, which is lead in a conventional way and results in solidification of the sol during thermomagnetic treatment at 350-400°C.
  • the core according to the invention is used in electrical apparatus, and especially in power transformer having a decreased level of audible noise during their exploitation.
  • amorphous Core 1 (about 140mm by 250mm, 20 mm thick, weighing about 3.3kg) of 40mm wide Metglas 2605 SA1 with the distributed gap portion was produced with introducing the organometallic binder at the lower yoke and leg components only.
  • the organometallic binder after thermomagnetic treatment at 370°C has a form of a film layer which bonded the lamination layers of the core, creating the improved amorphous metal magnetic core.
  • a reference amorphous Core 2 with the distributed gap was manufactured according to the state-of-the-art procedure in which the lateral edges or "faces" were coated with an epoxy resin, which was solidified then.
  • the core loss level was measured for all cores at 50 Hz and varying magnetic induction B is given in Table 1.
  • the composite Core 1 revealed slightly decreased core loss than the reference Core 2 after the edge coating, indicating that the organometallic binder, even if penetrating between the laminations, did not produce any substantial stresses in the core. Thus, the manufacturing technology of the present invention do not degrade the magnetic properties of the cores.
  • Table 1. Core Loss [Watts/kg] Induction B [Tesla] Core 2 Core 1 epoxy fixation organometallic binder 1.3 0.27 0.20 1.4 0.32 0.24
  • the low no-load loss amorphous metal magnetic core was manufactured in this way, having self-supporting functionality with the mechanical resistance.
  • the Core 1 could be handled without permanent deformation.
  • the present invention provides the manufacturing technology of the improved amorphous magnetic cores with decreased level of the emitted sound power, good mechanical stability and with no degraded magnetic properties.

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

Claims (12)

  1. Verfahren zur Herstellung eines amorphen Magnetkerns (1, 1'), welches das Zusammenfalten mehrerer aus Streifen eines amorphen Metalls erzeugten Laminierungsschichten (6, 6'), die ein Bandkern (1) oder ein Faltkern (1') bilden, wobei der Bandkern (1) zwei parallele Flächen (9) hat, die von den Kanten der Laminierungsschichten (6) geformt sind und über Mittel zum Einschränken der Form des Kerns (1) während seiner Herstellung verfügt, und der Faltkern (1') seitliche Flächen (9') hat, die von den Kanten der Laminierungsschichten (6') geformt sind, dadurch gekennzeichnet, dass es folgende Schritte umfasst:
    - Den Schritt der Einführung zwischen die benachbarten Laminierungsschichten (6, 6') des jeden Kerns (1, 1') entsprechend von einem metallorganischen Bindemittels (11, 11a) zum Formen von mehreren Dünnfilmen (8, 8'), wobei der Wärmeausdehnungskoeffizient von Dünnfilmen (8, 8') niedriger als der Wärmeausdehnungskoeffizient der Laminierungsschichten des Kerns (6, 6') ist und jeder Dünnfilm (8, 8') über den ganzen Querschnitt des Kerns (1, 1') senkrecht zu den beiden Flächen (9) des Bandkerns (1) bzw. zu allen Seitenflächen (9') des Faltkerns (1') verteilt ist und
    - Den Schritt der Verbindung von Laminierungsschichten (6, 6') mit den Dünnfilmen (8, 8') durch Glühen des Kerns (1, 1') bei der Temperatur von 350-400 °C und in einem Magnetfeld von über 800 A/m, bei welchem die mit den Dünnfilmen (8, 8') verbundenen Laminierungsschichten einen Kern (1, 1') bilden, wodurch das hörbare Geräusch während des Einsatzes des Kerns reduziert wird.
  2. Das Verfahren gemäß Anspruch 1, dadurch gekennzeichnet, dass als metallorganisches Bindemittel (11, 11a) ein flüssiges Sol eingesetzt wird.
  3. Das Verfahren gemäß Anspruch 2, dadurch gekennzeichnet, dass das flüssige Sol die Viskosität von 0,1 cps (0,1 mPa·s) bis 50 cps (50 mPa·s) hat.
  4. Das Verfahren gemäß den Ansprüchen 1-3, dadurch gekennzeichnet, dass als metallorganisches Bindemittel ein einzelnes siliziumorganisches Sol oder eine Mischung von unterschiedlichen siliziumorganischen Solen eingesetzt werden.
  5. Das Verfahren gemäß jeglichem der o.a. Ansprüche, dadurch gekennzeichnet, dass der Schritt der Einführung des metallorganischen Bindemittels (11) zwischen die benachbarten Laminierungsschichten (6, 6') des Kerns durch das Auftragen mit einem Pinsel auf mindestens einem Teil der Fläche (9) oder der von den Kanten der Laminierungsschichten (6, 6') geformten Seitenflächen (9') erfolgt.
  6. Das Verfahren gemäß den Ansprüchen 1-4, dadurch gekennzeichnet, dass der Schritt der Einführung des metallorganischen Bindemittels (11) zwischen die benachbarten Laminierungsschichten des Kerns durch das Eintauchen von mindestens einem Teil des Kerns (1, 1') in dem flüssigen Sol erfolgt.
  7. Das Verfahren gemäß den Ansprüchen 1-4, dadurch gekennzeichnet, dass der Schritt der Einführung des metallorganischen Bindemittels (11) zwischen die benachbarten Laminierungsschichten des Kerns durch das Aufsprühen des metallorganischen Bindemittels (11a) auf die Laminierungsschichten (6, 6') vor dem Schritt der Zusammenlegung von mehreren aus Streifen des amorphen Metalls erzeugten Laminierungsschichten (6, 6') zwecks Gestaltung des entworfenen Kerns erfolgt.
  8. Die amorphe magnetische Struktur des Kerns (1, 1'), zusammengesetzt aus den Laminierungsschichten (6, 6'), welche aus Streifen des amorphen Metalls erzeugt sind, und aus den Dünnfilmen (8, 8'), welche aus dem zwischen die benachbarten Laminierungsschichten (6, 6') eingeführten metallorganischen Bindemittel (11, 11a) erzeugt sind, und in welcher der Wärmeausdehnungskoeffizient jedes Dünnfilms (8, 8') niedriger als die Wärmeausdehnungskoeffizienten der benachbarten Laminierungsschichten (6, 6') ist, zusammen mit der aus den mit Dünnfilmen (8, 8') verbundenen Laminierungsschichten (6, 6') geformten Struktur bilden den Kern (1, 1'), wodurch das hörbare Geräusch während des Einsatzes des Kerns reduziert wird
  9. Die Struktur des Kerns gemäß Anspruch 8, dadurch gekennzeichnet, dass jeder der Dünnfilme (8, 8') in dem Raum zwischen zwei benachbarten Laminierungsschichten (6, 6') angebracht ist und die Dünnfilme (8, 8') im Kontakt mit den zwei gegenüberliegenden Flächen der benachbarten Laminierungsschichten (6, 6') sind.
  10. Der Kern gemäß den Ansprüchen 8-9, dadurch gekennzeichnet, dass der Wärmeausdehnungskoeffizient der Laminierungsschichten (6, 6') ungefähr 7,8 x 10-6 [1/K] beträgt.
  11. Ein elektrisches Gerät mit einem Kern (1, 1'), welcher die Struktur gemäß den Ansprüchen 9-10 aufweist.
  12. Ein elektrisches Gerät gemäß Anspruch 11, welches ein Netztransformator oder ein Verteilertransformator ist.
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CN107273628A (zh) * 2017-06-26 2017-10-20 浙江群力电气有限公司 一种地下配电室的温度场计算方法及系统
CN111091967B (zh) * 2018-10-24 2021-11-19 哈尔滨工业大学 一种磁聚焦霍尔推力器的线圈固化方法
CN111785489A (zh) * 2019-04-04 2020-10-16 青岛云路先进材料技术股份有限公司 一种变压器、非晶合金立体卷铁芯及其制备方法
DE102020212993A1 (de) 2020-10-15 2022-04-21 Siemens Energy Global GmbH & Co. KG Verfahren zur Verringerung einer von einem Eisenkern eines Transformators ausgehenden Geräuschbelastung, Eisenkern sowie Transformator
CN112635176A (zh) * 2020-11-30 2021-04-09 上海置信日港电气有限公司 一种非晶合金铁芯的降噪方法

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NL8501491A (nl) * 1985-05-24 1986-12-16 Philips Nv Magneetkern.
US7235910B2 (en) * 2003-04-25 2007-06-26 Metglas, Inc. Selective etching process for cutting amorphous metal shapes and components made thereof
TWI522235B (zh) * 2011-08-31 2016-02-21 杰富意鋼鐵股份有限公司 具絕緣覆膜的電磁鋼板
US8427272B1 (en) * 2011-10-28 2013-04-23 Metglas, Inc. Method of reducing audible noise in magnetic cores and magnetic cores having reduced audible noise

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