EP3224840B1 - Module élémentaire de noyau magnétique de transformateur électrique, noyau magnétique le comportant et son procédé de fabrication, et transformateur le comportant - Google Patents

Module élémentaire de noyau magnétique de transformateur électrique, noyau magnétique le comportant et son procédé de fabrication, et transformateur le comportant Download PDF

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EP3224840B1
EP3224840B1 EP14824098.9A EP14824098A EP3224840B1 EP 3224840 B1 EP3224840 B1 EP 3224840B1 EP 14824098 A EP14824098 A EP 14824098A EP 3224840 B1 EP3224840 B1 EP 3224840B1
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core
magnetic
winding
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EP3224840A1 (fr
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Thierry Waeckerle
Alain Demier
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Aperam SA
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Aperam SA
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/25—Magnetic cores made from strips or ribbons
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/33—Arrangements for noise damping
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F3/14—Constrictions; Gaps, e.g. air-gaps
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • 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)
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F2003/106—Magnetic circuits using combinations of different magnetic materials
    • 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 to the field of electrical transformers capable of being carried on board aircraft. Their function is the galvanic isolation between the source network and the on-board electrical and electronic systems, as well as the voltage transformation between the primary circuit (network side supplied by the on-board generator(s)) and one or more several secondary circuits.
  • these transformers can be "rectifiers" by a downstream functionality based on electronic components, in order to deliver a constant voltage to certain on-board devices.
  • Low-frequency on-board transformers consist mainly of a magnetic core in soft magnetic alloy, laminated, stacked or wound according to construction constraints, and primary and secondary winding(s) in copper.
  • the primary supply currents are variable over time, periodic but not necessarily of purely sinusoidal form, which does not fundamentally change the needs of the transformer.
  • the transformer should be operated on a roughly sinusoidal frequency supply network, with an amplitude of the output rms voltage which may vary transiently by up to 60% from moment to moment, and in particular during the energization of the transformer or during the sudden engagement of an electromagnetic actuator. This has the consequence, and by construction, of a current inrush at the primary of the transformer through the nonlinear magnetization curve of the magnetic core.
  • the elements of the transformer (insulators and electronic components) must be able to withstand strong variations in this inrush current without damage, which is called the “inrush effect”.
  • the noise emitted by the transformer due to electromagnetic forces and magnetostriction must be low enough to comply with current standards or to meet the requirements of users and personnel stationed near the transformer.
  • pilots and co-pilots of aircraft wish to be able to communicate no longer using headsets but by direct voice.
  • the thermal efficiency of the transformer is also very important to consider, since it fixes both its internal operating temperature and the heat flows that must be evacuated, for example by means of an oil bath surrounding the windings and the cylinder head, associated with oil pumps sized accordingly.
  • the sources of thermal power are mainly Joule effect losses from the primary and secondary windings, and magnetic losses from variations in the magnetic flux over time d ⁇ /dt and in the magnetic material.
  • the thermal power density to be extracted is limited to a certain threshold imposed by the size and power of the oil pumps, and the internal operating limit temperature of the transformer.
  • the cost of the transformer must be kept as low as possible in order to ensure the best technical and economic compromise between material, design, manufacturing and maintenance costs, and optimization of the electrical power density (mass or volume ) of the device by taking into account the thermal regime of the transformer.
  • the criteria to be taken into consideration to assess it are mainly the saturation magnetization Js and the magnetic induction at 800 A/m B 800 .
  • the transformer comprises a wound magnetic circuit when the power supply is single-phase.
  • the core structure of the transformer is made by two toroidal cores of the previous type joined, and surrounded by a third torus wound and forming an "8" around the two previous toric cores.
  • This form of circuit imposes in practice a small thickness of the magnetic sheet (typically 0.1 mm). In fact, this technology is only used when the power supply frequency makes it necessary, taking into account the induced currents, to use strips of this thickness, that is to say typically for frequencies of a few hundred Hz.
  • a stacked magnetic circuit is used, whatever the thicknesses of the magnetic laminations envisaged. This technology is therefore valid for any frequency below a few kHz. However, particular care must be taken with deburring, juxtaposition, and even efficient electrical insulation of the sheets, in order to reduce both the parasitic air gaps (and therefore optimize the apparent power) and limit the induced currents between the sheets. .
  • an Fe-48% Co-2% V alloy optimized for transformer has a B800 of approximately 2.15 T ⁇ 0.05 T, which allows an increase in magnetic flux to 800 A/m for the same cylinder head section approximately 13% ⁇ 3%, at 2500 A/m approximately 15%, at 5000 A/m approximately 16%.
  • the two materials can have relatively little different magnetostrictions and magnetic losses.
  • the respective saturation magnetizations of the materials are not considered, nor the influence of the construction of the core on the inrush effect.
  • JP H08-250337 describes a coiled core of Si steel (for example 6.5% Si) with low noise, fragile, the cracking of which is to be avoided under the effect of vibrations and thermal stresses.
  • this core is surrounded on its two internal and external peripheries by sheets of Si steel with lower magnetostriction than those of the central part of the core, containing 3% of Si, grain oriented (see ⁇ 9° They represent 4-20% of the total mass of the core.
  • the core therefore has three superimposed windings.
  • the respective magnetostrictions of the different materials are not specified quantitatively, nor are the details of their respective magnetic properties.An influence of the construction of the nucleus on the inrush effect is not mentioned.
  • DE-A-1 813 643 discloses a low-noise suppression coil having a bilayer closed core, in particular for the suppression of semiconductor circuits, for which the properties required are not the same as those of the cores of aeronautical transformers, in particular on magnetic losses which, in the cores of interference suppression coils, must be high to result in the creation of induced currents.
  • a low magnetostriction material is effectively required in the cores of DE-A-1 813 643 , but it must be placed inside the kernel.
  • US-A-5,160,379 describes a soft magnetic alloy applicable in particular to transformers, mainly comprising Fe, which may contain Ni or Co, containing Cu, Si and/or B, and at least one metal chosen from Nb, W, Ta, Zr, Hf, Ti, Mo, and a crystal size of less than 1000 ⁇ .
  • JP H03-271 346 describes a soft magnetic alloy relatively comparable to those of the previous document, but necessarily containing Nb, W, Ta or Mo.
  • JP S55-88313 describes a three-phase Evans-type transformer core fitted locally with spacers to stiffen its assembly, and thus reduce the noise caused by its oscillations. It relates, essentially, to the classic three-phase transformer core design that the invention aims to improve,
  • EP-A-1 742 232 shows three-phase transformer cores consisting of two elementary modules and an additional winding surrounding them. These cores are composed of magnetic laminations of different characteristics, arranged in such a way as to obtain a uniform distribution of the magnetic flux inside the core. This makes it possible to reduce the no-load losses (iron loss) of the transformer. The problems of magnetostriction noise reduction and the inrush effect are not mentioned, as well as the means which would make it possible to obtain them.
  • JP H4 074403 describes a transformer of small size and reduced weight, of the "armored transformer” type, comprising two cores which interpenetrate and one of which is made of a “low magnetostriction” material such as Fe-Si 6.5 %.
  • WO-A-2011/107387 (D9) describes non-immersed transformer cores, in amorphous material, provided on their surface with a coating which encapsulates them and protects them from their environment (humidity, oxidation). This coating is at least one wound strip having interruptions.
  • the object of the invention is to propose a design of low-frequency electrical transformer, suitable for use in aircraft, and making it possible to best solve the technical problems just mentioned, and at the lowest cost.
  • the subject of the invention is an elementary magnetic core module of an electric transformer according to claim 1.
  • the elementary module preferably comprises one or more of the characteristics of claims 2 to 5.
  • the invention also relates to a magnetic core of a single-phase electric transformer according to claim 6.
  • the invention also relates to a single-phase electrical transformer according to claim 7.
  • the invention also relates to a magnetic core of a three-phase electric transformer according to claim 8.
  • the magnetic core preferably includes one or more of the features of claims 9 to 15.
  • the invention also relates to a three-phase electrical transformer according to claim 16.
  • the invention also relates to a method of manufacturing a single-phase electric transformer core according to claim 17.
  • the invention also relates to a method of manufacturing a three-phase electrical transformer core according to claim 18.
  • the method preferably includes one or more of the features of claims 19 to 23.
  • Transformer noise comes from two sources: magnetic forces and magnetostriction from the magnetic materials used in the cores of these transformers.
  • the noise resulting from the magnetic forces can be reduced quite easily in a closed magnetic circuit with very low distributed air gaps, by mechanical systems suitable for holding the various elements made of electromagnetic materials (conductors and magnetic sheets).
  • Magnetostrictive phenomena must be considered with several magnitudes of deformation ( ⁇ 100 , ⁇ 111 , ⁇ sat ) or energy.
  • the magnetostriction constants ⁇ 100 and ⁇ 111 represent the amplitude of the coupling between local magnetization and lattice deformation along the crystallographic axes ⁇ 100>, respectively ⁇ 111>.
  • This coupling is therefore also anisotropic with respect to the crystallographic reference, so that for a supposedly uniform magnetization of the metal (and, therefore, of direction given in the reference of the sample, and therefore also of specific direction in each of the crystals considered ), each crystal would tend to deform differently from its neighbor (the crystallographic orientations being necessarily different), but will be prevented from doing so by intergranular mechanical cohesion.
  • the resulting elastic stresses which can be represented in a simplified way by a quantity ⁇ i , generate a magnetoelastic energy, of order of magnitude (3/2) ⁇ i which partially demagnetizes the material (in this expression, ⁇ approximately represents an average magnetostriction of the same order of magnitude as the constants ⁇ 100 and ⁇ 111 ).
  • ⁇ approximately represents an average magnetostriction of the same order of magnitude as the constants ⁇ 100 and ⁇ 111 .
  • the application of an external stress also degrades performance: this is the opposite effect of magnetostriction.
  • These magnetostriction constants ⁇ 100 and ⁇ 111 very mainly depend on the composition, and also on the crystallized fraction in the case of a nanocrystalline material, and they are known for a certain number of materials.
  • ⁇ sat is the apparent saturation magnetostriction.
  • the quantities ⁇ 100 and ⁇ 111 relate to the magnetostriction deformations along the ⁇ 100> and ⁇ 111> axes of a monocrystal free to deform.
  • the behavior of an industrial material introduces the internal elastic stress ⁇ i due to the different crystallographic orientations present, which amounts to hindering the deformation of each of the crystals. This results in an overall magnetostriction, called "apparent magnetostriction" of the material, measured from the demagnetized state, and having no rigorous explicit relationship with the constants ⁇ 100 and ⁇ 111 , other than the same order of magnitude.
  • This apparent magnetostriction ⁇ sat is determined after saturation, and therefore represents the maximum amplitude of deformation of the material when it is magnetized, relative to its starting state "demagnetized” or not, which is in all cases an initial state of deformation unknown.
  • ⁇ sat is therefore a variation in the state of deformation between two poorly identified states.
  • ⁇ sat is thus a use value which intervenes in the first order in the vibration of the magnetic laminations, the noise emitted or the compatibility of deformation between the magnetic material and its immediate vicinity (for example the packaging of a magnetic component core passive, field sensor, signal transformer, etc.).
  • the on-board network was for a long time at a fixed frequency of 400 Hz, but the variable frequency (typically 300 Hz to a few kHz) supplied directly by the generators is increasingly being used.
  • the variable frequency typically 300 Hz to a few kHz supplied directly by the generators is increasingly being used.
  • these relatively low “medium frequencies” it is advantageous to have a material with high induction and low losses (the thermal dimensioning also conditions the volume and mass of the transformer), such as thin Fe-Co alloys, thin Fe-Si electrical steels GO or NO high saturation amorphous, possibly Fe-6.5%Si.
  • This domain frequency corresponds to skin thicknesses of less than 1/10 mm, which is completely compatible with the need for thicknesses of this type in the case of a wound-type magnetic core technology according to the invention. Above 0.1 mm, it is more and more difficult to roll the metal in toroidal form.
  • the magnetic losses of an on-board transformer core should not exceed 20 W/kg of installed magnetic material, preferably less than 15 W/kg, and better still less than 10 W/kg, for a maximum induction of 1 T under a sinusoidal field at a frequency of 400 Hz (this corresponds to 2 T/400 Hz at respectively less than 80 W/kg, and preferably less than 60 W/kg and, better still, less than 40 W /kg). This condition must be met by the materials of all the transformer core windings.
  • the nanocrystalline material FeCuNbSiB given as an example in the various tables has the typical composition Fe 73.5 Cu 1 Si 15 B 7.5 Nb 3 .
  • Table 1 Technical characteristics of different magnetic materials for embedded transformers Material Thickness (mm) ⁇ el ( ⁇ .cm) ⁇ vol (kg/m 3 ) Magnetic losses at 1T (in W/kg) B t (T) Hm (B t ) (in A/m) 400Hz 1kHz 5kHz 400Hz 1kHz FeSi-NO 0.1 48 7650 11 33 350 1.8 5000 5500 FeSi-GO 0.05 48 7650 8 22 200 1.8 80 90 Fe-50%Co 0.1 45 8200 7.5 23 250 2.1 500 550 Amorphous 2605SC 0.025 125 7320 1.6 6 65 1.5 40 64 Amorphous 2605CO 0.025 130 7560 4.5 18 210 1.6 40 60 Fe-6.5/Si 0.1 75 7400 6 17 180 1.2 60 60 Fe-50%Ni (Supra 50) 0.05 48 8200 3 10
  • the work induction B t is used to dimension the magnetic circuits (FeSi, FeCo) when the frequency does not exceed 1 kHz, because the magnetic losses remain modest, therefore easy to evacuate. Beyond 1 kHz, the losses make it necessary to use a larger cooling system or to impose a reduction in B t (due to the fact that the losses are linked to the square of B t ): the iron-based amorphous then appear as an alternative interesting (lower B t but much lower losses): indeed the lower saturation magnetization Js of amorphous metals is then no longer a disadvantage, while their low magnetic losses represent a strong advantage.
  • the maximum inrush current (transient magnetizing current of a transformer) is proportional to (2B t + B r - B s ) where B t is the nominal work induction (resulting from the sizing of the magnetic circuit), B r is the remanent induction of the magnetic circuit (namely of the assembly consisting of the ferromagnetic core and the air gaps located or distributed according to the construction structure of the core), and B s is the saturation induction of the core.
  • the ideal magnetic circuit comprises an alloy with high saturation magnetization (FeSi, FeCo) and low remanence, used at reduced induction: this requires optimized design and sizing of the magnetic circuit and an adequate calibration of the air gap(s) from these materials with high magnetization at saturation Js.
  • Table 2 Expected properties of materials that can be used to form a single-material core Material Thickness (mm) H c (A/m) B t (T) Power density Acoustic noise emitted Magnetic losses A.tr and conductor losses Inrush effect Cost ideal material excellent excellent excellent excellent excellent excellent excellent Fe3%Si-NO 0.1 40-50 1.8 very good poor poor poor excellent Fe3%Si-GO 0.1 20 1.8 very good weak good good poor excellent Fe3%Si-GO 0.05 25 1.8 very good weak very good good poor excellent Fe3%Si-GO 0.05 25 1 weak good very good Very well good excellent Fe3%Si-GO 0.05 25 0.5 Wrong Very well excellent excellent excellent excellent excellent Fe-50%Co 0.1 56 2.1 excellent Wrong poor poor poor weak Fe-50%Co 0.05 54 2.1 excellent Wrong weak poor poor weak Fe-50%Co 0.05 54 0.5 poor good Very well Very well excellent weak Amorphous base iron 2605CO 0.025 4 1.6 very good poor Very well very good weak weak Amorphous base iron 2605CO 0.025 4 1 weak good
  • the elementary module of the invention is a magnetic core, of the wound type known per se, but made by combining two different soft magnetic materials, in different proportions.
  • One, majority in cross section (in other words in volume since all the elements of the module have the same depth), is distinguished by a weak magnetostriction, the other, minority in cross section, is distinguished by a strong magnetization at saturation Js and serves as a mechanical support for the first material, as an inrush limiter, and has a minor but not insignificant participation in the transformation of energy in steady state.
  • These materials may optionally be present with identical sections/volumes, but the material with high saturation magnetization Js must not exceed in section/volume the material with low magnetostriction.
  • the inventors were, in fact, surprised to find that in such a configuration, the nanocrystalline cores (materials with low magnetostriction) wound around the first core wound and previously manufactured in crystalline material with high saturation magnetization (Fe, Fe-Si , Fe-Co...) not only were well held mechanically since the support is preserved here (not only as a mechanically useful part, but above all as an essential part for the electromagnetic operation of the transformer), but that the power density obtained remained at the same level as that of an unsupported nanocrystalline core.
  • the disadvantages which would be linked to an absence of support namely the geometric instability of the nanocrystalline core, and the possible alterations in the operation of the transformer which would result therefrom.
  • composite structure means that the structure uses several magnetic materials of different natures. It is constituted as follows, and assembled in the order which will be exposed.
  • the structure first comprises a winding 1, 2 of two magnetic sub-cores each made from a strip of material consisting of a material with high magnetization at saturation Js and low losses, such as Fe-3% alloys Grain-oriented Si, Fe-6.5% Si alloys, Fe-15 alloys with a total of 55% Co, V, Ta, Cr, Si, Al, Mo, Ni, Mn, W textured or not, the soft iron and ferrous steels and alloys consisting of at least 90% Fe and having a coercive field Hc of less than 500A/m, ferritic Fe-Cr stainless steels containing 5 to 22% of Cr, 0 to 10% in total of Mo, Mn, Nb, Si, Al, V and more than 60% Fe, non-oriented Fe-Si-Al electrical steels, Fe-Ni alloys containing 40-60% Ni with not more than 5% additions total amounts of other elements, Fe-based magnetic amorphs containing 5-25% total B, C, Si, P and more than 60% Fe, 0-20% total
  • These two windings 1, 2 each constitute the (inner) winding support of one of the two internal magnetic sub-cores of the transformer.
  • this winding is self-supporting after extraction from the winding machine, but it can itself be wound on a more rigid support that is as light as possible so as not to weigh down the transformer too much, this support being made of any type of material, magnetic or not.
  • windings 1, 2 of the inner magnetic sub-core The function of these windings 1, 2 of the inner magnetic sub-core is to dimensionally stabilize the final magnetic circuit in C, and also to absorb the very high A.trs and the transients which occur during power-up, during connection of the transformer to the network, during the sudden inrush of power from a load... and which cause a high inrush current in the transformer (inrush effect).
  • This sub-part 1, 2 in high Js material, in a transformer sized for a much lower nanocrystalline work induction (slightly below the Js of a low magnetostriction material, i.e. ⁇ 1.2 T) will be then magnetized to saturation for the duration of the inrush (which varies from a few seconds to 1 to 2 min.) from B t .
  • the skin thickness is 0.05 to 0.2 mm (depending on the material, frequency and permeability of the medium). Therefore, a winding of material with high Js having an insufficiently low thickness compared to the thickness of the skin would shield the external field coming from the windings, and this all the more so as there would be a large number of turns of metal with high Js in the winding. It is therefore preferable to use a material with high Js of low thickness (0.05 to 0.1 mm).
  • nanocrystalline or cobalt-based amorphous on the one hand ( ⁇ r at 1 kHz > 50,000 - 100,000) and thin FeSi or FeCo alloys ( ⁇ r at 1 kHz ⁇ 3000), or also Fe-80% Ni alloys by sufficiently reducing their thickness ( ⁇ 0.07mm) on the other hand.
  • Table 3 examples of materials with high Js that can be used in the invention In weight In ppm Alloy Co Whether CR V VS min Al O NOT S B800(T) B8000(T) 1 15 0.02 0.05 ⁇ 0.005 0.017 0.25 0.01 70 22 8 2.08 2.24 2 15 1.0 0.03 0.1 0.016 0.27 0.02 48 17 11 1.95 2.18 3 18 0.05 0.04 ⁇ 0.005 0.017 0.32 0.02 56 31 7 2.12 2.30 4 18 1.0 0.007 ⁇ 0.005 0.017 0.29 ⁇ 0.01 62 25 ⁇ 5 2.00 2.23 5 10 0.03 0.05 ⁇ 0.005 0.019 0.33 ⁇ 0.01 47 22 ⁇ 5 2.01 2.12 6 27 0.03 0.5 ⁇ 0.005 0.015 0.30 0.01 82 28 6 2.03 2.28 7 48 0.008 0.07 2.0 0.019 0.28 0.02 63 19 9 2.10 2.35 8 0 3.0 0.007 ⁇ 0.005 0.017 0.27 0.01 51 18 ⁇ 5
  • the structure then comprises two additional windings 3, 4. They are each superimposed on one of the windings 1, 2 of high Js material previously described, "superposed" meaning that the additional winding 3, 4 is arranged around the corresponding winding 1, 2 of high Js material which was previously produced.
  • These additional windings 3, 4 are made with a strip of a material having both low magnetic losses and low magnetostriction, such as polycrystalline alloys Fe-75 at 82% Ni-2 at 8% (Mo, Cu, Cr, V), cobalt-based amorphous alloys, and, very preferably, FeCuNbSiB and similar nanocrystalline alloys.
  • a particularly recommended polycrystalline material with about 80% Ni is also known as Mumetal. It achieves very low magnetostriction for a composition of 81% Ni, 6% Mo, 0.2 to 0.7% Mn, 0.05 to 0.4% Si, the remainder being iron, and for appropriate heat treatment d optimization of magnetic performance, well known to those skilled in the art.
  • a particularly recommended nanocrystalline material known to those skilled in the art since the 1990s, is renowned for its very low magnetic losses from low frequencies down to 50-100kHz and for its ability to tune its magnetostriction, via the compositions adequate and adequate heat treatments, to a value of zero or very close to 0.
  • composition is given by the formula (the subscript figures corresponding to atomic percentages as is customary in the definition of such materials): [Fe 1-a Ni a ] 100-xyz- ⁇ - ⁇ - ⁇ Cu x Si y B z Nb ⁇ M' ⁇ M' ⁇ with a ⁇ 0.3; 0.3 ⁇ x ⁇ 3; 3 ⁇ y ⁇ 17, 5 ⁇ z ⁇ 20, 0 ⁇ ⁇ ⁇ 6, 0 ⁇ ⁇ ⁇ 7, 0 ⁇ ⁇ ⁇ 8, M' being at least one of the elements V, Cr, Al and Zn, M" being at least one of the elements C, Ge, P, Ga, Sb, In and Be, having a relative permeability ⁇ r of between 30,000 and 2,000,000, a saturation of more than 1 T, and even 1.25 T when the composition is optimized to achieve zero magnetostriction.
  • the nanocrystalline material shrinks approximately 1% from its initial amorphous band state. This phenomenon must therefore be taken into account in advance in the winding of the amorphous strip around the first part 1, 2 of the inner sub-core made of high Js material, before the nanocrystallization annealing. Otherwise the 1% shrinkage on the first part of the core can lead to very strong internal stresses on the two materials of the core, which makes the whole fragile to the point of risking breakage and increases the magnetic losses. Conversely, this retraction promotes the mechanical joining of the two types of materials, and therefore promotes, if it is not excessive, a better dimensional stability of the C-shaped parts after impregnation and cutting.
  • Each of these bi-material windings (1, 3; 2, 4) constitutes an internal magnetic sub-core (called “elementary module”), defining a space 5, 6 in which two of the primary windings 7, 8, 9 will be inserted. of the three phases of the transformer and two of the secondary windings 10, 11, 12 of the three phases of the transformer.
  • transformer is single-phase, only one of these elementary modules alone constitutes the magnetic core of the transformer.
  • the structure then comprises a winding 13, which is disposed around the assembly formed by said two internal magnetic sub-cores closely joined along one of their sides.
  • the winding 13 is formed from a strip of material with low magnetic losses and low magnetostriction, such as Fe-75 alloys at 82% Ni - 2 at 8% (Mo, Cu, Cr, V), alloys cobalt-based amorphous alloys, and very preferably nanocrystalline FeCuNbSiB and related alloys as defined above.
  • This winding 13 forms part of the external magnetic sub-core.
  • a section of material 13 denoted S 13
  • S 3 or S 4 which have been wound in material with low magnetostriction in the inner subnuclei.
  • ratios S 3 /S 13 or S 4 /S 13 a value of 0.8 to 1.2 to compensate for the differences in the perimeter of the winding and the possible differences in air gap between the different materials which we will talk about later. far.
  • the structure then comprises a new winding 14 superimposed (in the sense seen above with regard to the internal magnetic sub-cores) around this part 13 with low magnetic losses and low magnetostriction of the external magnetic sub-core.
  • This new winding 14, whose section will be denoted S 14 is formed from a strip of material with high Js and low losses, such as Fe-3% Si-GO, Fe-6.5% Si, Fe-15 at 55% (Co, V, Ta, Cr, Si, Al, Mn, Mo, Ni, W) textured or not, soft iron and various steels, ferritic stainless steels Fe-Cr at 5 to 22% Cr, 0-10% total Mo, Mn, Nb, Si, Al, V and more than 60% Fe, Fe-Si-Al NO (non-oriented) electrical steels, Fe-Ni alloys close to 50% Ni, iron-based magnetic amorphous.
  • This final winding 14 completes the supply of magnetic material in what constitutes the wound yoke of the transformer.
  • the parts 3, 4 and 13 with low magnetic losses and low magnetostriction will have identical sections, or of the same order of magnitude, whereas the sections of materials with high Js and low losses of the first windings of the two sub-cores, 1 and 2 on the one hand, and the final winding 14 on the other hand, can be quite significantly different within the limits which are specified.
  • the nanocrystallization heat treatment of the windings 3, 4, 13 with low magnetic losses and low magnetostriction, if necessary, can be carried out at At the end of this stage, all the metallic materials having been assembled. But due to the contraction of the material 3, 4, 13 during the nanocrystallization, one is exposed after annealing to a detachment of the second winding 14 of the external sub-core with respect to the first winding 13 of the external sub-core, making much more difficult the "joining together" of the assembly before cutting. It is therefore preferable to apply this annealing at the end of the previous step, as said previously.
  • this step of setting up the winding 14 with low magnetic losses and low magnetostriction of the external sub-core it is, on the other hand, advisable to apply by deposition, or by prior bonding of the strips, or by impregnation under vacuum (or any other suitable process) a resin, an adhesive, a polymer, or another comparable substance, which will transform the whole of the magnetic yoke wound into a resistant one-piece body with high dimensional stability under stress. Hooping can possibly replace this bonding or this impregnation, or precede it.
  • the magnetic yoke thus formed is cut so as to divide the different sub-cores into two parts 15, 16 to form two elementary "half-circuits", after using the different technologies for immobilizing the strips of material and the sub-cores previously cited.
  • These two parts 15, 16 are intended to be separated by an air gap 17 as shown in the figure 1 .
  • the cutting must be done by firmly holding the magnetic yoke, within the limit of the mechanical resistance of the solidified core, and by any cutting process such as wire abrasion, cutting, water jet, laser, etc. . It is preferable to divide the cylinder head into two symmetrical parts as shown, but an asymmetry would not be contrary to the invention.
  • the surfacing or the calibration of the air gap 17 are not absolutely necessary for the invention, but they allow a better adjustment of the performance of the transformer. This makes it possible to increase inrush performance, and to make the characteristics of the transformers of a production series more reproducible.
  • the "replacement" or “assembly” of the two parts 15, 16 of the cut magnetic circuit, and possibly surfaced and wedged, can in particular be carried out by means of tightening by shrinking also using a high Js material having properties comparable to those of the material used in the winding 14, and therefore also participating (but without air gap) in attenuating the inrush effect like the other high Js materials.
  • This option is particularly interesting because it makes it possible to further lighten the magnetic circuit, while giving it strong mechanical cohesion.
  • the section of material with high Js compared to the total section, on the one hand for each sub-core taken alone, and, on the other hand, for the magnetic core taken as a whole, is worth from 2 to 50%, and preferably 4 to 40%. Therefore, this section is most generally in the minority, and in any case not in the majority, in the elementary module defined externally by the winding 14 of strip of material with high Js superimposed on the winding 13 of strip of low magnetostriction and in each of the elementary modules of the internal sub-kernel.
  • the ratio of the winding sections between materials with high Js (S 1 , S 2 , S 14 ) and materials with low magnetostriction ⁇ (S 3 , S 4 , S 13 ) must be maintained for each elementary module in a range determined for the invention to be implemented satisfactorily.
  • the proportion of high Js material (in terms of section ratios), relative to the total of the sections of the two types of materials, must be between 2 and 50%, and preferably between 4 and 40%. This can result in the following inequalities: 2 ⁇ 100 .
  • S 2 S 2 + S 4 ⁇ 50 of preference 4 ⁇ 100 .
  • S 14 S 13 + S 14 ⁇ 50 of preference 4 ⁇ 100 .
  • the material with high Js becomes predominant in section in the sub-cores and/or the core ( ⁇ 50%), then its mass unnecessarily weighs down the structure. As has been said, it only actively participates significantly in damping the inrush effect, whereas in steady state of the transformer, we want the material with high Js to only magnetize weakly. so as not to emit noise (it inevitably has medium to strong apparent magnetostriction).
  • the sizing of the transformer to achieve the desired power is essentially based on the material with low magnetostriction ⁇ . If we had less than 50% low ⁇ material (50% or more high Js material), essentially only this minority section would participate in the electrical transformation. Consequently, the high Js material is limited to a maximum of 50% of the total section of magnetic materials present in the sub-cores and the core of the transformer, as stated above.
  • the elementary half-circuits formed by the parts 15, 16 are very dimensionally stable, in particular after impregnation with a varnish and polymerization, even under the constraints of maintaining the two C-shaped parts of the elementary magnetic core. This would not be the case if the high Js parts 1, 2 were removed, which serve as mechanical supports for the low magnetostriction windings 3, 4, and stiffen each elementary core.
  • the magnetic alloys with low magnetostriction and low magnetic losses of the windings 3, 4 make it possible to satisfy most of the required requirements, in particular the very low acoustic noise emitted, even when one places oneself at a work induction B t close to saturation. This makes it possible in this case to maximize the power density, in particular in the case of nanocrystalline materials where it is possible to work up to 1.2 T. This is the other material, at high Js, of the winding 14 the outer part of the core which contributes the most to the damping of the inrush effect.
  • High Js alloys are characterized by medium (FeSi, FeNi, iron-based amorphous) to high (FeCo) amplitude magnetostriction, which makes it necessary to reduce the work induction B t very significantly (typically to at most 0.7T) to achieve low acoustic noise.
  • the inrush effect is sufficiently damped and distributed over the two types of material, and the noise emitted by each of the materials remains low, while allowing a fairly high power density, in any case better than what is known in the state of the art for solutions in which a low magnetostriction noise is primarily sought.
  • FIG 2 a single-phase transformer core 18, characterized by a rectangular-oblong shape of height h, width l and depth p, on which rests the winding of the main active material of the transformer: the material with low magnetostriction.
  • This elementary core 18 can also be integrated into a three-phase transformer circuit as shown in the figure 1 as an elementary module.
  • This oblong circuit single-phase transformer module is made with a first material with high Js, of winding thickness ep1, and with a second material with low magnetostriction wound around the first material itself wound beforehand, and having a thickness of winding ep2.
  • a and c are also the dimensions of the inner sides of the windings 3, 4 of the second material, with low magnetostriction, arranged around the windings 1, 2 of the material with high Js.
  • ep2 is equal to 20 mm.
  • ep1 is comprised, according to the tests, between 0 (absence of material at high Js) and 20 mm.
  • the depth p is variable according to the tests, because it is designed so that the power transferred is substantially the same in all the tests (of the order of 46 kVA), taking into account that the values of a and c are also the same in all tests. It will be noted (see Table 4) that p can reach values as high as 265 mm for a reference test 4 using an Fe49Co49V2 alloy alone and 176 mm for the reference test 8 using a FeSi3 alloy alone.
  • the reference solutions making use of a single nanocrystalline and the solutions of the invention which make use of a nanocrystalline and a material with high Js have a depth p that is markedly lower. In the examples according to the invention, it is of the order of 60 to 80 mm.
  • the transformer is supplied with electric current of nominal frequency 360 Hz.
  • the primary supply current has an intensity of 115 A with a number of turns N 1 generally equal to 1 turn, but being 5 turns in reference example 1 and 2 turns in reference examples 2, 3 and 4, taking into account the considered air gaps of each winding 1 and 2 on the one hand, 3 and 4 on the other hand, also taking into account the material considered for each winding (therefore of its permeability), in order to reach the work induction B t .
  • a voltage of 230 V is applied to the primary.
  • the energy conversion system in which the transformer is integrated requires that to provide a constant voltage variation V 1 of 230 V. This also amounts to supplying a constant three-phase power of 46 kVA.
  • the length of the magnetic circuit of the first material ranges from 270 to 343 mm in all the examples according to the invention and also in all the reference examples with an elementary bi-material module.
  • the inrush effect comes from the combination of the magnetic behaviors of the two materials, and in order to appreciate the innovative contribution of the presence of another magnetic material (the first material) in the core, the rolled thickness ep1 of this first material varies from 0 (which corresponds to an absence of the first material) to 20 mm depending on the tests. This corresponds to a magnetic circuit length which varies from 0 to 343.2 mm.
  • the noise comes from the magnetostriction of the materials and their level of magnetization, and therefore the noise will be mainly linked in steady state to the magnetic behavior of the second material.
  • the noise emitted by the various examples made of wound transformer cores is measured by a set of microphones placed around the transformer, in the mid-plane of the magnetic yoke.
  • the material(s) is (are) rolled up according to the basic structure defined previously.
  • Another possibility consists in precisely adjusting the air gaps (after cutting) ⁇ 1 and ⁇ 2 between the half-circuits of the windings of the first and second materials respectively, by giving them, if necessary, different values during the shaping of the cutting zones, in order to to be able to limit the magnetization of one material relative to the other. Otherwise certain uncontrolled levels of magnetization of material 1 could increase the magnetostriction or the inrush effect too much. It should, however, be remembered that the increase in an air gap increases the current necessary for the magnetization at the level B t , and therefore degrades the efficiency of the transformer. A balance will therefore have to be found between the advantages and disadvantages of the practical use of this solution.
  • the material with high Js FeCo greatly exceeds the induction of 1 T in the steady state of the transformer, and the noise of the FeCo then becomes predominant and unsatisfactory (much higher than 55 dB), but may be admissible for the duration of the Inrush effect (ie from a few fractions of a second to a few seconds).
  • the specifications for this aeronautical transformer are that the noise must be a maximum of 55 dB, at least outside the periods during which the inrush effect is felt, and the inrush factor less than or equal to 1, with the lowest possible magnetic core mass. Also, the total mass of magnetic materials should not exceed about 6.5 kg. We will see that for this last condition to be fulfilled at the same time as the other two, the total section of the high Js material relative to the total section of magnetic materials in the core exceeds 50%. This condition must also be respected if we reason on each of the internal and external sub-nuclei taken in isolation. In order not to complicate Table 4, only the ratio of the total sections has been specified there, but it must be understood that all the examples according to the invention also meet the condition for each of their sub-cores.
  • Examples 1 to 12, 18, 18B, 19 to 21 inclusive of Table 4 are therefore reference examples, and Examples 13 to 17 inclusive, 18C, 22 to 24 inclusive are examples according to the invention which meet all the criteria of the specifications as defined above.
  • the Js of the different materials are 2.00 T for FeCo27, 2.35 T for FeCo50V2, 2.03 T for FeSi3, 1.25 T for nanocrystalline.
  • Table 4 Performance of different core configurations tested Second material First material Steady state Mass and section Ex. Materials 2 + 1 thickness 2 mm thickness 1 mm P mm B, matte. 2 B t,2 (T) Br matt. 2 Br (T) B t matt. 1 B t,1 (T) d ⁇ /dt (V) Noise (dB) Inrush index Matt mass. 1 (kg) Matt mass. 2 (kg) Total mass (kg) % weight of mat. 1 (at high Js % section of mat. 1 (at high Js) Three-phase power (kVA) Matt air gap.
  • the nanocrystalline solution alone necessarily requires the use of a temporary or permanent winding support. In the case where it is permanent, it increases the mass of the nanocrystalline circuit as we have just said.
  • reference examples 12 nanocrystalline alone
  • 17 according to the invention nanocrystalline composite core cycle coated or cut + FeCo27
  • the noise emitted is lower for the 100% nanocrystalline solution (41 dB against 52 dB for the coated or cut cycle nanocrystalline composite core solution + FeCo27), but in both cases the noise is below the admissible threshold of 55 dB.
  • Example 12 uses a mass of nanocrystalline material of 5.0 kg, to which must be added a minimum mass of 200 to 300 g of non-magnetic Teflon, aluminum or stainless steel. Two possible cases have been considered for this example: permanent support and non-permanent support.
  • Table 5 cites the successive operations in these three embodiments, and compares the orders of magnitude of the costs of each step (from +: inexpensive to +++: expensive; 0: step absent from the embodiment) of the solutions in the case of making a functional sub-assembly of a single toroid (single-phase transformer type): Table 5: Cost comparison of solutions 12 (reference) and 17 (invention) Step no. 100% nanocrystalline solution (n°12), non-permanent support Stage cost 100% nanocrystalline solution (n°12), permanent support Stage cost Solution according to the invention (No.
  • Table 5 shows that there are fewer operations in the case of the invention, and, moreover, some of the operations common to the various solutions are less costly in the case of the invention. Indeed, when cutting and assembling C parts in 100% nanocrystalline material (example 12 without permanent mechanical support), the absence of stiffening mechanical support (case “without permanent support”) requires maintaining the C carefully, therefore using appropriate clamping jigs so as not to deform and damage the parts.
  • the FeCo support constitutes a mechanical core avoiding irreversible mechanical deformations, and is at the same time used functionally on the electromagnetic and electrical plane.
  • the 100% nanocrystalline solution of the prior art is either a little more expensive because of the greater number of operations and heavier because of the mass of the support ( case of the permanent support), or (case of the non-permanent support) of equal or slightly higher mass, but in any case much more expensive to produce. It therefore does not constitute, overall, a satisfactory solution to the problems which the invention sought to solve.
  • Example 21 By further increasing the proportion of FeCo, and therefore by making the magnetic circuit heavier (case of more than 30% by weight and more than 50% by section of FeCo, examples 19, 20 and 21), we see that the effect of inrush can be drastically reduced to a negative index. In this case, the magnetic circuit reaches a mass of around 7 kg (for a zero inrush index). This mass can however be considered a little too high for this technical solution to be fully satisfactory, especially since, moreover, the noise is only relatively slightly below the acceptable maximum of 55 dB (examples 19 and 20 ) or is above this acceptable maximum (example 21). A mass of the order of 6.5 kg would generally be considered acceptable, but only if, moreover, the noise and inrush conditions are respected. This explains why Example 21 is not considered to be part of the invention.
  • the picture 3 summarizes the performance of different possible magnetic circuit solutions in an inrush-noise index diagram where the transformer masses corresponding to the different points are also specified.
  • the dotted lines show the maximum noise values of 55 dB and the inrush index of 1 required by the specifications cited above.
  • This last point, which is also part of the specifications, also makes it possible to guarantee that the core of the transformer is very light, of the order of 6.5 kg or less.
  • the Inrush Index is always a strictly decreasing function of the mass of the magnetic yoke. But this curve is not linear, and it makes it possible in the case of the example analyzed to determine magnetic yoke solutions with fairly low mass (4 to 6.5 kg) for an already very low inrush index. In a different way, the noise depends not only on the mass, but also on the choice of the material(s) used (via their magnetostrictive properties).
  • High Js materials can be used in the same magnetic core, for example a Goss textured Fe-3%Si alloy in the inner winding of the inner sub-cores and an Fe-50%Co alloy in the outer winding of the sub - outer core.
  • Several materials with low magnetostriction can be used in the same magnetic core, such as, for example, a nanocrystalline FeCuNbSiB alloy of the composition specified above, in the inner winding of the inner sub-cores and an amorphous cobalt base in the winding. exterior of the outer subnucleus. It is best to use the same material for both inner sub-cores. It is preferable to keep the rule of conservation of the magnetic flux “J s .Section” between the three sub-parts concerned with materials with low magnetostriction.
  • nanocrystalline materials is recommended with respect to the use of other types of materials with low magnetostriction.
  • nanocrystalline materials of FeCuNbSiB composition mentioned which constitute privileged but not exclusive examples of materials that can be used for the implementation of the invention, are known to make it possible to adjust their magnetostriction to 0 by an adequate heat treatment, while their magnetization at saturation remains relatively high (1.25 T), therefore conducive to not making the transformer too heavy (see the dimensioning principles already mentioned influencing d ⁇ /dt and the inrush).
  • the invention is not only valid for a three-phase structure with two sub-cores placed side by side and nested in a third sub-core, but is also applicable to a simple magnetic core of a single-phase transformer, or to any other nesting of a higher number of magnetic sub-cores, for example in the case of polyphase transformers with more than three phases.
  • a person skilled in the art will be able without difficulty to adapt the design of the transformer according to the invention to this latter case.
  • the cutting of the finished magnetic core, forming the air gap 17, so as to better fill the winding window and therefore to reduce the mass/volume of the magnetic core, is not essential, but it is very preferable both for the previous reason since the power density is increased, via the optimal filling of the winding window, but also to lower the remanent induction of the magnetic circuit.
  • An additional advantage of the cut is to be able to possibly differentiate the air gaps ⁇ 1 and ⁇ 2 of the two materials, in order to better control the maximum level of magnetization of the first material with high Js and high magnetostriction.
  • the adjustment of the air gap can therefore be different between materials with low magnetostriction and materials with high Js, as we have seen on most of the examples according to the invention in table 4 and as represented on the figures 1 and 2 .
  • the magnetostriction is very low, the cyclic deformation of the materials will be very low and the air gap wedging will only propagate and amplify little noise.
  • materials with high Js very magnetostrictive, even for low work inductions in steady state (less than 0.8 T, or even less than 0.4 T) the vibrations may still be sufficient to generate noise above the highest requirements. In this case it may be preferable to machine a slight air gap, greater than that of the material with low magnetostriction, so that the materials with high Js are not in contact with the wedge, which makes it possible to reduce the emission of noise.
  • ⁇ 1 and/or ⁇ 2 for the various parts of the core, in other words. that the air gaps ( ⁇ 1, ⁇ 2) separating the two parts of the various windings (1, 2, 3, 4, 13, 14) are not all identical between the internal magnetic sub-core and the external magnetic sub-core.
  • the surfacing of the cut faces of the magnetic core is not essential, but it is preferable because it allows a better dimensioning of the performances of the transformer. This makes it possible to increase inrush performance, and to make transformers more reproducible during industrial production.
  • Calibrating the air gap using a wedge is not essential, but it is preferable to precisely adjust the remanent induction (linked in particular to the inrush effect) and the maximum level of magnetization accessible in each material, and to make more reproducible processors in industrial production.
  • the cutting symmetry of the magnetic core is not essential.
  • the different materials do not necessarily have the same width.
  • three strips of FeCuNbSiB nanocrystallizable amorphous of width l each can be wound around a pre-wound torus of internal FeSi or FeCo sub-core of width 3l. This brings the advantage of providing the same mechanical winding support for the FeCuNbSiB strips which are especially easy to produce and use when their width is less than 20-25 mm, whereas the needs for the magnetic cores of on-board transformers can greatly exceed such widths.
  • All materials, or only some of them, can be wound in the amorphous or work-hardened or partially crystallized state (depending on the case), or else be wound in the nanocrystallized state (FeCuNbSiB), relaxed (amorphous iron base or cobalt base) or crystallized (Fe-80%Ni, FeCo, FeSi, other polycrystalline materials).

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CN103918048B (zh) 2011-11-08 2016-09-28 株式会社东芝 非接触受电装置用磁性片材和使用该磁性片材的非接触受电装置、电子设备、以及非接触充电装置
RU2517300C2 (ru) * 2011-12-07 2014-05-27 Федеральное государственное унитарное предприятие Производственное объединение "Север" Способ управления статическим преобразователем в системе генерирования электрической энергии переменного тока в режиме короткого замыкания

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CA2968791C (fr) 2021-12-14
WO2016083866A1 (fr) 2016-06-02
KR102295144B1 (ko) 2021-08-30
RU2017117916A (ru) 2018-11-26
CN107735843B (zh) 2021-01-05
CN107735843A (zh) 2018-02-23
US20170345554A1 (en) 2017-11-30
RU2017117916A3 (ja) 2018-11-26
US10515756B2 (en) 2019-12-24
BR112017010829B1 (pt) 2022-06-21
JP6691120B2 (ja) 2020-04-28
CA2968791A1 (fr) 2016-06-02
WO2016083866A9 (fr) 2017-11-30
EP3224840A1 (fr) 2017-10-04
ES2926667T3 (es) 2022-10-27
JP2018502446A (ja) 2018-01-25
RU2676337C2 (ru) 2018-12-28
MX2017006878A (es) 2017-08-15
KR20170087943A (ko) 2017-07-31

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