EP3503134B1 - Holding device for holding a soft-magnetic stacked core of a transformer and transformer - Google Patents

Description

Technical field

The invention relates to a holding device for holding a soft magnetic transformer stack core with layers with an amorphous and / or nanocrystalline microstructure made of an iron alloy, in particular an FeSiB alloy, the transformer stack core having at least two coil legs running parallel to one another and two yokes connected to mutually opposite ends of the coil legs , and wherein the holding device has at least two holding units, each of which can be arranged on one of the two yokes such that the holding units are arranged at mutually opposite end regions of the transformer stack core, and at least one mechanical fixing means acting on the two holding units, by means of which the two holding units can be released without being destroyed are interconnected.

Furthermore, the invention relates to a transformer, in particular a three-phase transformer, having at least one soft-magnetic transformer stack core with layers with an amorphous and / or nanocrystalline structure made of an iron alloy, in particular an FeSiB alloy, the transformer stack core having at least two coil legs running parallel to one another and two with opposing ones Has ends of the coil legs connected yokes, and at least one holding device for holding the transformer stack core.

State of the art

Transformers convert an AC input voltage into an AC output voltage that differs from the AC input voltage. Transformers are used, for example, for voltage conversion in power supply systems and in electrical devices.

A transformer has a primary coil and a secondary coil for each phase of the input AC voltage to be converted, which are arranged on a common transformer core, which is made of ferromagnetic materials or ferrites. In conjunction with the coils, the transformer core bundles the magnetic flux and increases the inductance and the magnetic flux density of the transformer. The transformer core can be formed from a laminated core from a plurality of mutually electrically insulated transformer laminations. As a result, eddy current losses of the transformer during voltage conversion can be reduced.

A three-phase transformer has a soft magnetic transformer core, which has three coil legs running parallel to one another and two yokes connected to the end of the coil legs. A primary coil and a secondary coil of the same current phase are arranged on each coil leg. One of the yokes can be monolithically connected to the three coil legs, whereby an E-shaped section of the transformer core is formed. After the coils have been arranged on the coil legs, the second yoke can be connected to the free ends of the coil legs.

DE 10 2009 048 658 A1 discloses a conventional transformer stack core, comprising soft magnetic layers of an electrically conductive core material with an amorphous and / or nanocrystalline structure, which are separated from one another by separating layers of an electrically insulating material. Several of the soft magnetic layers form a monolithic bond, at least with the separating layers between them. The transformer stack core thus consists of a laminated core, the transformer laminations each consisting entirely of a monolithic composite of soft magnetic layers and separating layers. To produce the transformer stack core, a soft magnetic layer made of an electrically conductive core material is electrochemically deposited on a base body. An electrically insulating separating layer is produced on the soft magnetic layer. These processes are repeated until the transformer stack core has reached the intended shape. At least one soft magnetic element, in particular one or more of the elements iron (Fe), nickel (Ni) or cobalt (Co), and at least one glass-forming element, in particular phosphorus (P) and / or boron (B), are combined as the soft magnetic layer deposited.

The formation of a transformer stack core using soft magnetic amorphous layers is accompanied by a reduction in the losses on the transformer stack core during its use in a transformer. This is due to the lower magnetic coercive force, so that hysteresis losses when magnetizing the transformer stack core can be kept small.

DE 10 2011 083 521 A1 relates to a conventional press frame structure for a transformer with a plurality of tension elements, with a plurality of struts which are at least partially obliquely projecting from a core of the transformer, and with a plurality of tension pressure plates which are arranged on or near the core of the transformer. The tension elements are arranged outside the windings of the transformer. The tension elements are connected to the tension plates using the struts. The tension elements connect the upper press frame of the transformer with the lower press frame of the transformer. The tension elements cause the core to be clamped between the two press frames.

CN 102 543 384 B . CN 202 443 832 U. and WO 00/02211 A1 disclose a holding device according to the preamble of claim 1. CN 203 312 000 U. and CN 201 594 447 U disclose a holding device with an anti-vibration element between the holding unit and the transformer stack core.

Disclosure of the invention

An object of the invention is to provide a more energy-efficient transformer, in particular a three-phase transformer, of the type mentioned at the beginning.

This object is solved by the independent claim 1. Advantageous refinements are given in the dependent claims, the description below and the figures, these refinements, taken on their own or in a different combination of at least two of these refinements, can represent an advantageous and / or further aspect of the invention. Advantageous configurations of the holding device can correspond to advantageous configurations of the transformer, and vice versa, even if this is not explicitly referred to in the following.

A holding device according to the invention is used to hold a soft magnetic transformer stack core with layers with an amorphous and / or nanocrystalline microstructure made of an iron alloy, in particular an FeSiB alloy, the transformer stack core having at least two coil legs running parallel to one another and two yokes connected to opposite ends of the coil legs. The holding device has at least two holding units, each of which can be arranged on one of the two yokes in such a way that the holding units are arranged at mutually opposite end regions of the transformer stack core, and at least one mechanical fixing means acting on the two holding units, via which the two holding units are detachably connected to one another in a non-destructive manner. Furthermore, the holding device has at least one spacer clamped between the holding units and at least one spring element which can be arranged between at least one holding unit and the transformer stack core, the holding device being designed in such a way that the spring element, when the transformer stack core is arranged on the holding device, by at least indirect contact with it the transformer stack core is elastically deformed.

The holding device according to the invention is designed as an inherently stable holding device, which means that the holding device can be brought into its holding state and held in it without other components, such as the transformer stacking core, being required to give the holding device stability. The holding device according to the invention is therefore in particular not designed in accordance with a conventional press frame, as is shown, for example, in DE 10 2011 083 521 A1 is disclosed. With such a conventional press frame, it is generally necessary to bring the press frame into a holding state and to hold it with the aid of the transformer core. Here, the transformer core is clamped between two frame elements, whereby relatively high clamping forces, for example in the amount of a few 10,000 N, act on the transformer core, in particular in order to be able to ensure a sufficient frictional connection or frictional connection between the layers of a conventional electrical sheet stack.

Correspondingly high clamping forces lead to mechanical tensions within the transformer core. In the case of a transformer stack core, that is to say a transformer core composed of a plurality of stacked layers which are electrically insulated from one another and are produced from an iron alloy, in particular an FeSiB alloy, with an amorphous and / or nanocrystalline structure, such mechanical stresses lead to a deterioration in energy efficiency and thus to higher losses of the transformer. This is particularly so because mechanical stresses in soft magnetic iron alloys affect the magnetic permeability of the iron alloys decrease. Magnetic permeability is a major factor influencing the material-specific magnetic loss (hysteresis loss). In particular, the very high magnetic permeability of iron alloys with an amorphous and / or nanocrystalline structure is disproportionately affected by mechanical stresses. This reduces the energy efficiency of the transformer stack core and the efficiency of the transformer. This is avoided with the present invention, since with the holding device according to the invention only the restoring force generated by the elastic deformation of the at least one spring element acts on the transformer stack core, which are significantly reduced compared to the conventional mechanical clamping forces described. In addition, according to the invention, the inherent stability of the holding device means that there is no need for a conventional frictional connection between the press bars resting on the yoke and at the connection points of the coil legs and the individual layers of the core layered from grain-oriented electrical sheets. In addition, by means of the at least one spring element, only specified, preset forces for fixing or holding transformer stack cores or coil windings are introduced into the inherently stable frame, which have a minimal influence on the transformer stack core. The introduction of force for holding the transformer stack core is very low (can be, for example, about 0.5 N / mm ² ) and is preset via the at least one spring element. Therefore, the energy efficiency of a transformer stack core with layers that are electrically insulated from one another and with an amorphous and / or nanocrystalline structure made of an iron alloy, in particular an FeSiB alloy, is not impaired by the holding device according to the invention.

This advantage is achieved according to the invention in particular in that the two holding units for producing the holding state of the holding device are braced against one another via the at least one rigid spacer by means of the at least one mechanical fixing means acting on the two holding units, so that the mechanical clamping forces are absorbed by the spacer and not be transferred to the transformer stack core. The two holding units can also be correspondingly braced against one another via two or more, for example four, mechanical fixing means. Between the two holding units two or more, for example four, spacers can also be clamped accordingly. For this purpose, the spacer can be made, for example, of a metal, a metal alloy or another rigid or dimensionally stable material. The spacer can run in the immediate vicinity of a coil leg or be in contact with a coil leg, or can be arranged so spaced from the coil leg that there is space between the spacer and the coil leg for the coils to be arranged on the coil leg.

The only forces that act on the transformer stack core held by the holding device according to the invention are the restoring forces generated by the elastic deformation of the at least one spring element. Such restoring forces are significantly lower than the mechanical clamping forces conventionally applied with a press frame. The forces acting on the transformer stack core can therefore be determined according to the present invention by the choice of the type and configuration of the spring element, the spring constant or elastic modulus of which causes the desired holding forces. The spring element can in particular have a linear or non-linear force-displacement curve. The transformer stack core can be acted upon by means of corresponding spring elements, for example in the x direction, y direction and z direction. For example, a spring element can be arranged in the region of a butt joint between a coil leg and a yoke.

The holding device can also have two or more corresponding spring elements which can be arranged at different locations between the respective holding unit or the holding units and the transformer stack core. The spring element can be, for example, a body formed from an elastomer, which is arranged on a single side of the transformer stack body or on two or more sides of the transformer stack body or is adapted to its shape. The elastomer body can, for example, be cuboid, plate-shaped or the like. Alternatively, the spring element can be designed as a compression spring, for example a coil spring, spiral spring or plate spring.

The holding device according to the invention is configured in its holding state in such a way that the transformer stack core without the at least one spring element with one certain game is arranged on the holding device. Only through the arrangement of the at least one spring element on the holding device and a direct or indirect contact of the transformer stack core with the spring element or via at least one additional component and the associated elastic deformation of the spring element is a positive connection between the transformer stack core and the holding device produced.

The at least one mechanical fixing means can be designed, for example, as a screw connection. A threaded shaft of such a screw connection can run through the spacer, for example a sleeve-shaped one, or can be arranged outside and spaced apart from the spacer. The sleeve-shaped spacer can be elongated and can have a polygonal, for example square or rectangular, or a round, for example circular, elliptical or oval, cross-sectional area.

The holding device according to the invention also has the advantage that an assembly of coils on a transformer stack core arranged on the holding device can be carried out relatively simply by first loosening the mechanical fixation device (s), so that a holding unit can then be removed, after which it can be removed Holding unit previously held yoke can be removed from the rest of the transformer stack core. The coils can then be applied to the coil legs of the transformer stack core, after which the yoke previously removed can be arranged on the remaining transformer stack core and then the previously removed holding unit can be arranged on the remaining holding device. Finally, the mechanical fixing means are tightened again in order to bring the holding device into the holding state.

The two holding units can each have an essentially U-shaped cross section and can be arranged on the respective yoke in such a way that they are not arranged exclusively on a side of the respective yoke facing away from the other yoke, but additionally a section of the respective yoke on both sides embrace, but without a positive connection between the respective holding unit and the respective yoke. As a result, the respective yoke can be supported laterally both on its side facing away from the other yoke and on its two longitudinal sides, in particular via at least one between the respective holding unit and the respective yoke arranged spring element, which is elastically deformed when the transformer stack core is arranged on the holding device by a given at least indirect contact with the transformer stack core, in particular with its respective yoke. Alternatively, two or more spring elements can also be provided to support the yoke.

The spring element (s) additionally compensate for manufacturing tolerances, as a result of which the required manufacturing accuracy of all components of the holding device and the transformer stack core can be reduced in a cost-reducing manner.

According to an advantageous embodiment, at least one holding unit has at least two holding elements which can be arranged on opposite yoke end regions of the respective yoke, at least one mechanical fixing means acting on the two holding elements, by means of which the two holding elements are detachably connected to one another in a non-destructive manner, at least one clamped between the holding elements Spacers and at least one spring element which can be arranged between at least one holding element and the respective yoke, the holding unit being designed such that the spring element is elastically deformed when the transformer stack core is arranged on the holding device by an at least indirect contact with the transformer stack core. As a result, the respective yoke can also be fixed in the transverse direction in that the yoke is clamped on the respective holding unit with elastic deformation of the spring element. The at least one spring element between the at least one holding element and the respective yoke additionally compensates for manufacturing tolerances, as a result of which the required manufacturing accuracy of all components of the holding device and the transformer stack core can be reduced in a cost-reducing manner.

According to this embodiment, too, only the restoring force generated by the elastic deformation of the at least one spring element between at least one holding element and the respective yoke acts on the transformer stack core, which are significantly reduced in comparison to the conventional mechanical clamping forces described above. The two holding elements are used to produce the holding state of the holding device by means of the at least one on the two holding elements attacking mechanical fixing means braced against each other via the at least one rigid spacer between the holding elements, so that the mechanical clamping forces are absorbed by the spacer and are not transmitted to the transformer stack core.

The two holding elements can also be correspondingly braced against one another via two or more, for example four, mechanical fixing means. Two or more, for example four, spacers can also be correspondingly clamped between the two holding elements. For this purpose, the spacer between the holding elements can be made, for example, of a metal, a metal alloy or another rigid or dimensionally stable material.

The forces acting on the transformer stack core can be determined by the choice of the type and design of the spring element between the respective holding element and the yoke, the spring constant or modulus of elasticity of which causes the desired forces. The holding device can also have two or more corresponding spring elements which can be arranged at different locations between the holding elements and the transformer stack core. The spring element can be, for example, a body formed from an elastomer, which is arranged on a single side of the transformer stack body or on two or more sides of the transformer stack body or is adapted to its shape. Alternatively, the spring element can be designed as a compression spring, for example a coil spring, spiral spring or plate spring.

The at least one mechanical fixing means acting on the holding elements can be designed, for example, as a screw connection. A threaded shaft of such a screw connection can run through the, for example sleeve-shaped, spacer between the holding units or can be arranged outside and at a distance from this spacer.

The two holding elements can each have an essentially S-shaped cross section and can be arranged on the respective yoke in such a way that they are not arranged exclusively on one side of the respective yoke facing away from the respective other yoke, but in addition a section of the respective yoke on one side reach around to the side. As a result, the respective yoke can both its side facing away from the other yoke, as well as laterally supported on its respective longitudinal side, in particular via at least one spring element arranged between the respective holding element and the respective yoke, which, when the transformer stack core is arranged on the holding device, by at least indirect contact with the transformer stack core , in particular with its respective yoke, is elastically deformed.

According to a further advantageous embodiment, at least one spring element is U-shaped in such a way that it positively engages around the transformer stack core along at least a section of the respective yoke in such a way that there is a connection area between at least one coil leg and the respective yoke between parallel legs of the spring element. As a result, the number of spring elements required can be reduced, which simplifies the assembly of an appropriately equipped transformer. The U-shaped spring element can encompass the respective yoke, for example, on the side facing away from the other yoke and on sections of the longitudinal sides adjoining it laterally. Since the connection area between the coil leg and the yoke is located between parallel legs of the spring element, this connection area is secured by the spring element in the course of a positive fit, which is particularly advantageous when the coil leg is connected to the yoke by means of a butt joint.

According to a further advantageous embodiment, the holding device has at least one spring element which can be arranged at least partially between the spacer and the transformer stack core, the holding device being designed such that the spring element is elastically deformed when the transformer stack core is arranged on the holding device by at least indirect contact with the transformer stack core is. In this way, for example, a coil leg connected to equilateral end sections of the yokes can be supported laterally. In addition, the end section can be supported on the end face by one of these yokes, the spring element extending over a connecting region between the yoke and the coil leg. The spring element can be supported directly or indirectly on the spacer and / or the transformer stack core and can in this case form a positive connection with the spacer and / or the transformer stack core.

According to a further advantageous embodiment, the holding device has at least one spacer which can be arranged between two adjacent coil legs and on which the two coil legs are laterally supported on one another. As a result, the coil legs can be supported indirectly against one another, which is particularly advantageous in the event of a butt joint between the respective coil leg and the respective yoke, since then the, in particular positive, connection between the coil leg and the yoke does not offer any lateral support. The spacer is preferably made of a non-conductive material. The spacer can be made of a rigid or resilient, in particular elastic, material.

According to a further advantageous embodiment, the holding device has at least two support elements that can be arranged on opposite sides of a coil leg, each of which is connected at the end, in particular in a form-fitting manner, to the two holding units. The support elements support the coil leg laterally via a positive connection and transfer the support forces to the holding units. Each support element can, for example, be plate-shaped or rod-shaped. Recesses are formed on the holding units, into which the end sections of the support elements engage in order to be supported laterally on sides facing away from one another.

According to a further advantageous embodiment, the holding device has at least four coil support elements for axially supporting coils arranged on one coil leg, two coil support elements being arranged on one holding unit and the two other coil support elements being arranged on the other holding unit, the coil support elements being arranged in pairs on opposite sides of the Coil legs can be arranged. Furthermore, the holding device according to this embodiment has at least one spring element arranged or to be arranged per coil support element either between the respective holding unit and the respective coil support element or between the respective coil support element and the respective coils, the holding device being designed in such a way that the spring element at the other Holding device arranged transformer stack core with coils arranged thereon is elastically deformed by a given at least indirect contact with the coils. As a result, the coils are supported separately from the transformer stack core on the holding device. This is an advantage since the coils, especially if they are coils with non-glued or loose windings, have to be fixed on the holding device with significantly higher mechanical tensioning forces than the transformer stack core. Correspondingly high mechanical clamping forces do not act on the transformer stack core due to the decoupling of the mechanical fixings of the transformer stack core on the one hand and coils on the other hand on the holding device. The spring elements according to this embodiment can each be formed, for example, from bodies made of an elastomer or as a compression spring. Alternatively, the coil support elements, which are arranged in the vicinity of the respective holding unit, can be connected to one another in order to form a monolithic coil support body, on which a separate opening is formed for each coil leg.

According to a further advantageous embodiment, a restoring force that can be applied with the respective spring element can be set separately. As a result, the restoring force can be changed afterwards, for example, adjusted or increased, or optimized. For this purpose, the spring element can be supported on a component of the holding device, the position of which can be varied relative to the remaining holding device. This component can be, for example, a screw body screwed into a screw hole on a holding unit or on a holding element. Two or more, in particular all, restoring forces that can be applied with the spring elements can also be correspondingly separately adjustable.

A transformer according to the invention, in particular a three-phase transformer, has at least one soft magnetic transformer stack core with layers with an amorphous and / or nanocrystalline microstructure made of an iron alloy, in particular an FeSiB alloy, the transformer stack core having at least two coil legs running parallel to one another and two ends opposite one another Has coil legs connected yokes. Furthermore, the transformer has at least one holding device for holding the transformer stack core, the holding device being designed with one another according to one of the above-mentioned configurations or any combination of at least two of these configurations.

The advantages mentioned above with reference to the holding device are correspondingly connected to the transformer. The iron alloy preferably contains at least a soft magnetic element, in particular one or more of the elements Fe, silicon (Si), Ni or Co, and at least one glass-forming element, in particular P and / or B. The glass-forming element is used to form the amorphous and / or nanocrystalline structure of the respective amorphous structure Layer. The amorphous layers are preferably electrically separated from one another.

At least one coil leg can be integrally and / or positively connected to at least one yoke. To produce the transformer stack core, for example, an E-shaped component can be produced, which has a section designed as a yoke and three sections designed as a coil leg. After the coils have been arranged on the coil legs, a separate yoke can be connected to the free ends of the coil legs. The yokes can be cuboid, while the coil legs can each have a stepped cross-sectional area. The cuboid design of the yokes means that they can be produced using less material, which reduces the costs for producing the transformer.

At least one coil leg can be connected to the respective yoke by a butt joint, that is to say at a cutting angle of 90 °. However, at least one coil leg can also be connected to the respective yoke using a different cutting angle, for example a cutting angle of 45 °. Alternatively, the connecting sections of the respective coil leg and the respective yoke can be formed in such a way that sections of the coil leg and yoke overlap one another. The overlapping sections can be integrally connected to one another. Alternatively, a connecting section of a coil leg can have so-called step-lap layering. The individual coil legs of a transformer stack core can be designed in various ways and connected to the respective yoke. In addition, at least one coil leg can be connected to at least one yoke in at least two different ways.

At least one joint surface of joint surfaces of a coil leg and a yoke to be connected to one another can be treated at least partially physically and / or chemically. As a result, the abutting surface can be provided with a desired surface roughness, for example. Treatment of Bump surface to create a plane parallelism between joint surfaces to be connected. Both joint surfaces to be connected can also be treated accordingly. The physical treatment can, for example, be mechanical, in particular machining, and / or thermal and / or chemical, for example etching.

In the transformer according to the invention, it is possible to first loosen the mechanical fixation device (s) by means of which the two holding units are connected to one another, and then, after removing the respective holding unit, to remove the yoke held therefrom for the assembly of coils on the coil legs to solve the remaining transformer stack core. Then the coils can be arranged on the coil legs. This process is much easier and quicker to carry out than a conventional assembly process, in which thousands of windings of a transformer core have to be stratified manually in order to arrange coils on the coil legs, and laboriously manually layered again after arranging the coils on the coil legs. The throughput of a plant for the manufacture of corresponding transformers can be significantly increased by the significantly faster possible manufacture of the transformer according to the invention.

According to an advantageous embodiment, the coil legs and the yokes are each formed by a stack of composite bodies which are integrally connected to one another, wherein each composite body is formed from interlinked, cut-to-length composite sections of a band-shaped multi-component composite, the multi-component composite having at least two composite layers joined to one another, each of which Composite layer is formed from a film composite, each film composite having at least two ribbon-shaped, soft magnetic films with an amorphous and / or nanocrystalline structure made of an iron alloy, in particular an FeSiB alloy, the films being integrally bonded to one another. Each amorphous film forms an amorphous layer of the transformer stack core. As a result, the transformer can be manufactured more cheaply and faster than, for example, the one in DE 10 2009 048 658 A1 disclosed transformer, especially since the individual layers of a transformer stack core are not corresponding DE 10 2009 048 658 A1 sequentially deposited, which is very time consuming.

The respective band-shaped, soft magnetic film with an amorphous and / or nanocrystalline structure made of an iron alloy, in particular an FeSiB alloy, can be continuously produced using a casting process, which is significantly faster than conventional successive deposition of individual layers of a particular shape and size. For the continuous production of the amorphous film, a melt can first be produced from the iron alloy, for example using an induction melting furnace. The melt can then be poured onto a rotating roller, where the melt is progressively cooled to form the amorphous film or solidifies to form the amorphous and / or nanocrystalline structure. The amorphous film formed in this way can be pulled off the roller and, after any further processing and / or processing steps, can be wound up to form a film roll. The amorphous film can then be unwound again for further process steps.

The fact that the amorphous film is produced continuously means that the amorphous film is not formed in a specific size and shape that is adapted to a size and shape of a soft magnetic component to be produced, but rather as an elongated band that has a length of, for example, several 10,000 can have m. The thickness of the amorphous film can range, for example, from approximately 20 μm to approximately 60 μm. The maximum width of the amorphous film can be, for example, in a range from approximately 180 mm to approximately 300 mm, in particular up to approximately 400 mm. With a thickness of approximately 25 μm, the length of the amorphous film can be, for example, 35,000 m.

Furthermore, the band-shaped film composite can be produced continuously by continuous, in particular planar or local, material bonding of the amorphous film with at least one correspondingly produced further amorphous film, which can also be carried out significantly faster than the conventional production of a special film composite by depositing individual layers, such as it for example DE 10 2009 048 658 A1 disclosed. The two amorphous films can be unwound from different film rolls simultaneously, for example, for the continuous production of the band-shaped film composite.

For example, an adhesive can be formed on at least one of the two unwound film sections to form the material bond between the amorphous films the further uncoiling of the amorphous films are applied continuously, for example by means of an application roller or by spraying on the adhesive. Alternatively, the adhesive can be applied in a dot-like manner or in lines. The adhesive forms an adhesive layer between two mutually adjacent amorphous films of the film composite, which can be electrically insulating in order to electrically separate the amorphous films from one another. As a result, eddy current losses at the transformer stack core can be kept as low as possible.

Alternatively, the adhesive layer can provide little or no electrical insulation, the electrical separation of the amorphous foils from one another being able to take place in a different way. For example, at least one main side of an amorphous film can be treated, for example by a diffusion process or the like, in such a way that a section of the amorphous film adjacent to the main page has a reduced electrical conductivity compared to the rest of the amorphous film, which is used for electrical insulation between them amorphous foils is used.

Alternatively, during the further uncoiling of the amorphous films, another agent, for example an oil, can be continuously applied to at least one of the two unwound film sections, which creates or strengthens adhesion between the amorphous films. The agent can alternatively be applied in punctiform fashion or in lines. Further alternatively, the material bond between the amorphous foils can be produced in that at least one connection side of at least one amorphous foil is at least partially heated and thereby partially melted before the amorphous foils are brought together, so that the molten material of this amorphous foil on the other amorphous foil solidifies and brings about the material bond.

To produce the film composite, the amorphous film can also be connected to two or more, for example two to seven, further amorphous films, the film composite thereby having a corresponding number of film layers. The film composite can then be wound up into a film composite roll in order to be available for further processing and / or processing steps. A film composite with five layers of amorphous films with a respective thickness of approximately 25 μm can be produced, for example, with a length of approximately 7,000 m become. The thickness of the film composite can be, for example, in a range from approximately 40 μm to approximately 400 μm.

Before reeling up the film composite, at least one electrically insulating separating layer can be applied continuously on at least one side to the film composite or can be formed on the film composite. This is particularly advantageous if the film composite is later to be connected to at least one correspondingly produced further film composite, since the film composites are then electrically separated from one another to reduce eddy current losses. Alternatively, an electrically insulating adhesive can also be used to connect the film composites. An electrically insulating separating layer can also be arranged on each side of the film composite. The film composite provided with the at least one separating layer can then be wound up to form a film composite roll in order to be available for further processing and / or processing. The separating layer can, for example, be formed on one side of the film composite by treating the corresponding main side of the film composite, for example by a diffusion process or the like, in such a way that a section of the film composite adjacent to the main side has a reduced electrical conductivity compared to the rest of the film composite , which is used for electrical insulation between interconnected foil composites.

The continuous application or formation of at least one electrically insulating separating layer on at least one face to or on the film composite can be carried out significantly faster than, for example, the deposition of separating layers DE 10 2009 048 658 A1 , The electrically insulating separating layer can be applied to the film composite by means of a continuous material connection, for example using a sprayed-on adhesive or other adhesive, of the film composite with a film forming the separating layer. The electrically insulating separating layer can be formed on the film composite, for example, by continuous application, for example by means of an application roller or by spraying, of an insulation material onto the film composite, which hardens as quickly as possible after its application to form the separating layer. Alternatively, the separation layer can be formed on the film composite by treating a main side of the film composite described above.

Before the film composite is produced, at least one electrically insulating separating layer can be applied continuously on at least one side to each of the films or can be formed on each of the films. The continuous application or formation of at least one electrically insulating separating layer on at least one surface over or on the respective amorphous film can also be carried out significantly faster than, for example, the deposition of separating layers DE 10 2009 048 658 A1 , The electrically insulating separating layer can be applied to the respective amorphous film by a continuous material connection, for example using a sprayed-on adhesive or another adhesive, the amorphous film with a film forming the separating layer. The electrically insulating separating layer can be formed on the respective amorphous film, for example, by continuous application, for example by means of an application roller or by spraying, on the insulating material onto the amorphous film, which hardens as quickly as possible after its application to form the separating layer. Alternatively, the separation layer can be formed on the respective amorphous film by treating a main side of the amorphous film as described above. An electrically insulating separating layer can also be arranged or formed on each side of the respective amorphous film. The respective amorphous film provided with the at least one separating layer can then be wound up into a film roll in order to be available for further processing and / or processing.

The continuous cohesive connection of the film composites to one another can take place by means of an adhesive or another adhesive which is applied continuously to at least one of the film composites by means of an application roller or by spraying. The adhesive or the adhesive can be electrically insulating. The width of the multi-component composite can be, for example, in a range from approximately 200 mm to approximately 1000 mm. The thickness of the multi-component composite can be, for example, in a range from approximately 40 μm to approximately 2000 μm.

The thickness of a composite body can be, for example, in a range from approximately 3 mm to approximately 400 mm. The width of a composite body can be, for example, in a range from approximately 30 mm to 1000 mm. The length of a composite body can be, for example, in a range from approximately 100 mm to 2500 mm. The composite sections can, for example, be selected, stacked and integrally bonded to one another in such a way that the respective composite body formed therefrom has, for example, a rectangular, trapezoidal or other cut surface. At least one groove or the like can also be formed on at least one side surface of the respectively formed composite body. The composite sections can be of different thicknesses, long and / or wide in order to produce a step-like bevel of the composite body formed therefrom. A width and / or length of the composite body is the same over a height of the stack or at least partially decreases in a step-wise manner in at least one end region of the stack with respect to the height, towards the free end of the end region.

The respective coil leg or the respective yoke can be produced by integrally connecting composite bodies of the same or different width and / or length, wherein a cross-sectional area of the coil leg or yoke by using composite bodies of different width or length on at least one corner region with a gradation is trained. As a result, the coil leg can be given, for example, an approximately circular, elliptical or oval cross-sectional area in cross-section, for which purpose each corner region is formed with a corresponding gradation. For example, the yoke can have a rectangular cross-sectional area. The composite bodies can be connected to one another by means of an adhesive or another adhesive. The adhesive or the adhesive can be electrically insulating.

According to a further advantageous embodiment, the composite layers are each formed from a longitudinally divided film composite, the one film composite being longitudinally divided at a different location with respect to a cross-sectional width of the respective multi-component composite than the further film composite arranged adjacent to the film composite. A multi-component composite of any width can be produced by staggering the arrangement of composite sections produced by the respective longitudinal division of the respective film composite and materially connecting the composite sections. The one film composite can be longitudinally divided, for example, at a single point in its cross-sectional area, while the further film composite can be longitudinally divided, for example, at two points in its cross-sectional area, which corresponds to the cross-sectional area of the first-mentioned film composite. The multi-component composite can be arranged alternately between these two composite foils are formed, wherein the multi-component composite can also be formed from more than two foil composites. The individual film composites can also have a different number of longitudinal divisions. For the formation of the multi-component composite, it is essential that longitudinal divisions of adjacent film composites are offset with respect to the longitudinal extent of the multi-component composite or are not aligned with one another in the thickness direction of the multi-component composite. Alternatively, the film composites of the composite layers are not correspondingly longitudinally formed.

In the following, the invention is explained by way of example with reference to the attached figures using preferred embodiments, the features explained below, both individually and in different combinations with one another, representing an advantageous and / or further aspect of the invention.

Brief description of the figures

Fig. 1

eine schematische und perspektivische Darstellung eines Ausführungsbeispiels für einen erfindungsgemäßen Transformator;

Fig. 2

eine schematische und perspektivische Darstellung der in Fig. 1 gezeigten Haltevorrichtung;

Fig. 3

eine schematische und perspektivische Teilschnittdarstellung eines Abschnitts des in Fig. 1 gezeigten Transformators;

Fig. 4

eine schematische und perspektivische Schnittdarstellung eines weiteren Abschnitts des in Fig. 1 gezeigten Transformators in einer ersten Variante;

Fig. 5

eine schematische und perspektivische Schnittdarstellung eines weiteren Abschnitts des in Fig. 1 gezeigten Transformators in einer weiteren Variante;

Fig. 6

eine schematische Schnittdarstellung eines weiteren Ausführungsbeispiels für einen erfindungsgemäßen Transformator;

Fig. 7

eine weitere schematische Schnittdarstellung des in Fig. 6 gezeigten Transformators; und

Fig. 8

eine schematische Schnittdarstellung eines weiteren Ausführungsbeispiels für einen erfindungsgemäßen Transformator.

Show it:

Fig. 1

is a schematic and perspective view of an embodiment of a transformer according to the invention;

Fig. 2

is a schematic and perspective view of the in Fig. 1 shown holding device;

Fig. 3

is a schematic and perspective partial sectional view of a portion of the in Fig. 1 transformer shown;

Fig. 4

is a schematic and perspective sectional view of a further portion of the in Fig. 1 shown transformer in a first variant;

Fig. 5

is a schematic and perspective sectional view of a further portion of the in Fig. 1 shown transformer in a further variant;

Fig. 6

a schematic sectional view of a further embodiment for a transformer according to the invention;

Fig. 7

another schematic sectional view of the in Fig. 6 transformer shown; and

Fig. 8

is a schematic sectional view of a further embodiment for a transformer according to the invention.

Detailed description of the figures

In the figures, identical or functionally identical components are provided with the same reference symbols. A repeated description of these components may be omitted.

Fig. 1 shows a schematic and perspective view of an embodiment for a transformer 1 according to the invention in the form of a three-phase transformer.

The transformer 1 has a soft magnetic transformer stack core 2 with layers, not shown, with an amorphous and / or nanocrystalline structure made of an iron alloy, in particular an FeSiB alloy. The transformer stack core 2 has three coil legs 3 running parallel to one another and two yokes 4 connected to opposite ends of the coil legs 3. Two coils 18 and 19 are arranged on each coil leg 3.

The coil legs 3 and the yokes 4 are each formed by a stack of integrally connected composite bodies, not shown, wherein each composite body is formed of integrally connected, cut, not shown composite sections of a band-shaped, not shown multi-component composite. The respective multi-component composite has at least two composite layers, not shown, which are bonded to one another, each composite layer being formed from a foil composite, not shown, each foil composite comprising at least two ribbon-shaped, soft-magnetic foils, not shown, with an amorphous and / or nanocrystalline structure made of an iron alloy, in particular an FeSiB alloy, the foils being integrally connected to one another.

The composite layers of the multi-component composite can each be formed from a longitudinally divided foil composite, not shown, the one foil composite being longitudinally divided at a different location with respect to a cross-sectional width of the respective multi-component composite, not shown, than the further foil composite arranged adjacent to the foil composite.

The transformer 1 also has a holding device 5 for holding the transformer stack core 2. The holding device 5 has two holding units 6 and 7, which are each arranged on one of the two yokes 4 such that the holding units 6 and 7 are arranged on opposite end regions of the transformer stack core 2.

Furthermore, the holding device 5 has four mechanical fixing means 8 which engage the two holding units 6 and 7 and by means of which the two holding units 6 and 7 are detachably connected to one another in a non-destructive manner. Each fixing means 8 is designed as a screw connection. The fixing means 8 are each arranged in a corner area of the holding device 5.

In addition, the holding device 5 has four spacers 9 clamped between the holding units 6 and 7, which are sleeve-shaped in the exemplary embodiment, a threaded shaft 39 of the respective fixing means 8 being guided through the respective spacer 9. The threaded shafts 39 of the fixing means 8 can be extended upwards beyond the holding unit 6 in such a way that they are additionally used to hold a cover (not shown) of a transformer tank (not shown).

Furthermore, the holding device 5 has a plurality of spring elements (not shown) arranged between the respective holding unit 6 or 7 and the transformer stack core 2. The holding device 5 is designed in such a way that the spring elements are elastically deformed when the transformer stack core 2 is arranged on the holding device 5 due to an at least indirect contact with the transformer stack core 2. At least one spring element can be U-shaped in such a way that it encompasses the transformer stack core 2 along at least a section of the respective yoke 4 in such a positive manner that there is a connection region (not shown) between at least one coil leg 3 and the respective one Yoke 4 is located between parallel legs of the spring element, not shown. A restoring force that can be applied with the respective spring element can be separately adjustable.

Each holding unit 6 and 7 has two holding elements 10 and 11, which are arranged on opposite yoke end regions of the respective yoke 4. Furthermore, each holding unit 6 or 7 has two mechanical fixing means 12 which engage the two holding elements 10 and 11 and by means of which the two holding elements 11 and 12 are detachably connected to one another in a non-destructive manner. In addition, each holding unit 6 or 7 has two spacers 13 clamped between the holding elements 10 and 11, which are sleeve-shaped in the exemplary embodiment, a threaded shaft 40 of the respective fixing means 12 being guided through the respective spacer 13. Each holding unit 6 or 7 furthermore has a plurality of spring elements (not shown) arranged between the respective holding element 11 or 12 and the respective yoke 4. The respective holding unit 6 or 7 is designed in such a way that the respective spring element is elastically deformed when the transformer stack core 2 is arranged on the holding device 5 due to an at least indirect contact with the transformer stack core 2. A restoring force that can be applied with the respective spring element can be separately adjustable.

The holding device 5 can also have at least one spring element (not shown) which is at least partially arranged between the respective spacer 9 and the transformer stack core 2, the holding device 5 being able to be designed such that the spring element when the transformer stack core 2 is arranged on the holding device 5 by at least one given indirect contact with the transformer stack core 2 is elastically deformed.

Furthermore, the holding device 5 can have at least one spacer, not shown, which is arranged between two coil legs 3 arranged adjacent to one another and on which the two coil legs 3 are laterally supported on one another. Corresponding spacers are for example in Fig. 6 shown.

The holding device 5 also has three pairs each of two support elements 14 arranged on opposite sides of the respective coil leg 3, each of which is connected at the end to the two holding units 6 and 7.

In addition, the holding device 5 has four coil support elements 15 per coil leg 3 for axially supporting the coils 18 and 19 arranged on the respective coil leg 3. For each coil leg 3, two coil support elements 15 are arranged on one holding unit 6 and the two other coil support elements 15 on the other holding unit 7. For each coil leg 3, the coil support elements 15 are arranged in pairs on opposite sides of the respective coil leg 3. As indicated by dash-dotted lines on the holding unit 7, coil support elements 15 running between adjacent coil legs 3 can be connected monolithically to one another.

Furthermore, the holding device 5 per coil support element 15 has two spring elements, not shown, which are arranged between the respective holding unit 6 or 7 and the respective coil support element 15 and each engage in an opening 16 in the respective holding unit 6 or 7. The holding device 5 is designed such that the spring elements, when the transformer stack core 2 is arranged on the holding device 5, with coils 18 and 19 arranged thereon, indicated by dash-dotted lines, are elastically deformed by at least one coil 18 or 19 via the coil support elements 15 are.

Fig. 2 shows a schematic and perspective view of the in Fig. 1 Holding device 5 shown. In particular, all four spacers 9 are shown.

Fig. 3 shows a schematic and perspective partial sectional view of a portion of the in Fig. 1 shown transformer 1. The coils are omitted, whereby the support elements 14 and their respective arrangement on the respective coil leg 3 can be seen better.

Fig. 4 shows a schematic and perspective sectional view of another section of the in Fig. 1 shown transformer 1 in the region of the holding element 11 of the holding unit 6 in a first variant. An opening 16 formed on the holding element 11 is shown, into which a pin 20 of the spring element 21 shown engages. On a support plate 22, which is formed by monolithically connecting coil support elements (not shown) arranged between adjacent coil legs 3, as shown in FIG FIGS. 1 and 3 is indicated, a separate depression 23 is formed for each spring element 21, in which the respective spring element 21 is partially included. A recess 25 is formed on a bottom 24 of the recess 23, into which a further pin 26 of the respective spring element 21 engages. Each spring element 21 is made monolithically from an elastomer.

Fig. 5 shows a schematic and perspective sectional view of another section of the in Fig. 1 shown transformer 1 in the region of the holding element 11 of the holding unit 6 in a second variant. An opening 16 formed on the holding element 11 is shown, into which a pin 17 of the plate-shaped spring element 27 shown engages. The spring element 27 is supported on one side on a support plate 28 which is formed by monolithically connecting coil support elements (not shown) arranged between adjacent coil legs 3, as shown in FIG FIGS. 1 and 3 is indicated. Each spring element 27 is made monolithically from an elastomer.

Fig. 6 shows a schematic sectional view of a further embodiment for a transformer 29 according to the invention in the form of a three-phase transformer. The transformer 29 differs essentially from that in FIGS FIGS. 1 to 5 Embodiment shown that the transformer stack core 2 is supported on the holding unit 6 and 7, respectively, by means of spring elements 30 and 31 of larger area and each by two further spring elements 32 on the spacers 33, which are arranged separately from the fixing means 8. Otherwise, the transformer 29 can correspond to the FIGS. 1 to 5 be trained, which is why to avoid repetition on the above description of the FIGS. 1 to 5 is referred. The holding device 5 also has four spacers 34 arranged in pairs between two adjacent coil legs 3, on which the respective two coil legs 3 are laterally supported on one another.

Fig. 7 shows a further schematic sectional view of the in Fig. 7 shown transformer 29 according to the section plane AA Fig. 6 , It can be seen that the spring elements 30 and 31 are each U-shaped in cross section. In each case a connecting area 35 between the respective yoke 4 and the respective coil leg 3 is arranged between parallel legs 36 of the respective spring element 36. Instead of the respective U-shaped spring element 30 or 31 can three separately shown elements, not shown, can be arranged correspondingly in a U-shape, one element forming a leg as a spring element and the other element forming a leg as a sliding body, while the element connecting these two elements can be formed as a spring element.

Fig. 8 shows a schematic sectional view of a further embodiment for a transformer 37 according to the invention in the form of a three-phase transformer. The transformer 35 differs in particular from that in FIGS FIGS. 6 and 7 Embodiment shown that each holding unit 6 or 7 is U-shaped in cross section and thus has two parallel legs 38, between which the respective spring element 30 or 31 is received. The mechanical fixing means of the holding unit 5 are not shown. Between the free ends of the legs 38 and at least one coil 18 or 19, a spring element 41 is arranged, which is elastically deformed by contact with the respective coil 18 or 19.

LIST OF REFERENCE NUMBERS

1

transformer

2

Transformer core stack

3

coil legs

4

yoke

5

holder

6

holding unit

7

holding unit

8th

Fixative of 5

9

Spacer of 5

10

retaining element

11

retaining element

12

Fixative of 6, 7

13

Spacers from 6, 7

14

support element

15

Coil support element

16

Breakthrough at 10, 11

17

Cones of 27

18

Kitchen sink

19

Kitchen sink

20

Cones of 21

21

spring element

22

support plate

23

Deepening on 22

24

Floor of 23

25

Recess at 23

26

Cones of 21

27

spring element

28

support plate

29

transformer

30

spring element

31

spring element

32

spring element

33

spacer

34

spacer

35

Connection area between 3 and 4

36

Thighs of 30, 31

37

transformer

38

Legs of 6, 7

39

Threaded rod of 8

40

Threaded rod of 12

41

spring element

Claims (11)

1. Holding device (5) for holding a soft-magnetic stacked transformer core (2) comprising layers having an amorphous and/or nanocrystalline structure made of a ferrous alloy, particularly of a FeSiB alloy, wherein the stacked transformer core (2) comprises at least two coil legs (3) running parallel to each other and two yokes (4) connected with opposite ends of the coils legs (3), comprising

   - at least two holding units (6, 7) that can be arranged in such a way at one of the yokes (4) that the holding units (6, 7) are arranged at opposite end regions of the stacked transformer core (2), and

   - at least one mechanical fixing means (8) acting on both holding units (6, 7), the holding units (6, 7) being nondestructively detachably connected with each other via the fixing means (8), characterized in that the holding device (5) comprises

   - at least one spacer (9, 33) clamped between said holding units (6, 7) and

   - at least one spring element (30, 31) arrangeable between at least one holding unit (6, 7) and the stacked transformer core (2),

   - wherein the holding device (5) is constructed in such a way that the spring element (30, 31) is elastically deformed by an at least indirect contact with the stacked transformer core (2) caused when the stacked transformer core (2) is arranged at the holding device (5).
2. Holding device (5) according to claim 1, characterized in that at least one holding unit (6, 7) comprises

   - at least two holding elements (10, 11) arrangeable at opposite yoke end regions of the respective yoke (4),

   - at least one mechanical fixing means (12) acting on both holding elements (10, 11), the holding elements (10, 11) being nondestructively detachably connected with each other via the fixing means (12),

   - at least one spacer (13) clamped between the holding elements (10, 11),

   - wherein the at least one spring element (30, 31) is arrangeable between at least one holding element (10, 11) and the respective yoke (4),

   - wherein the holding unit (6, 7) is constructed in such a way that the spring element (30, 31) is elastically deformed by an at least indirect contact with the stacked transformer core (2) caused when the stacked transformer core (2) is arranged at the holding device (5).
3. Holding device (5) according to claim 1 or 2, characterized in that the at least one spring element (30, 31) is U-shaped in such a way that, when the stacked transformer core (2) is arranged at the holding device (5), it positively encompasses the stacked transformer core (2) along at least one section of the respective yoke (4) in such a way that a connection region (35) arranged between the coil legs (3) and the respective yoke (4) is located between parallel legs (36) of the spring element (30, 31).
4. Holding device (5) according to one of the claims 1 to 3, characterized by at least one spring element (32) at least partly arrangeable between the spacer (33) and the stacked transformer core (2), wherein the holding device (5) is constructed in such a way that the spring element (32) is elastically deformed by an at least indirect contact with the stacked transformer core (2) caused when the stacked transformer core (2) is arranged at the holding device (5).
5. Holding device (5) according to one of the claims 1 to 4, characterized by at least one spacer (34) arrangeable between adjacent coil legs (3), at which the coils legs (3) being laterally supported against each other when the stacked transformer core (2) is arranged at the holding device (5).
6. Holding device (5) according to one of the claims 1 to 5, characterized by at least two support elements (14) arrangeable on opposite sides of a coil leg (3) and being connected at its ends with both holding elements (6, 7) when the stacked transformer core (2) is arranged at the holding device (5).
7. Holding device (5) according to one of the claims 1 to 6, characterized by

   - at least four coil support elements (15) for axially supporting of coils (18, 19) being arranged on a coil leg (3), wherein two coil support elements (15) are arranged at one holding unit (6, 7) and the two further coil support elements (15) are arranged at the other holding unit (6, 7), wherein the coil support elements (15) are arrangeable in pairs on opposite sides of the coil leg (3), and

   - at least one spring element (21, 27, 41) per coil support element (15) arrangeable either between the respective holding unit (6, 7) and the respective coil support element (15) or between the respective coil support element (15) and the respective coil (18, 19),

   - wherein the holding device (5) is constructed in such a way that the spring element (21, 27, 41) is elastically deformed by an at least indirect contact with at least one coil (18, 19) caused when the stacked transformer core (2) with the coils (18, 19) thereon is arranged at the holding device (5).
8. Holding device (5) according to one of the claims 1 to 7, characterized in that a reset force that can be applied by the respective spring element (21, 27, 30, 31, 32, 41) is separately adjustable.
9. Transformer (1, 29, 37), particularly three-phase transformer, comprising

   - at least one soft-magnetic stacked transformer core (2) comprising layers having an amorphous and/or nanocrystalline structure made of a ferrous alloy, particularly of a FeSiB alloy, wherein the stacked transformer core (2) comprises at least two coil legs (3) running parallel to each other and two yokes (4) connected with opposite ends of the coils legs (3), and

   - at least one holding device (5) for holding the stacked transformer core (2), characterized in that the holding device (5) is constructed according to one of the claims 1 to 8.
10. Transformer (1, 29, 37) according to claim 9, characterized in that the coil legs (3) and the yokes (4) each are constituted by a stack of compound bodies firmly bonded to each other, wherein each compound body is constituted by cut-to-length compound segments of a ribbon-like multi-compound, the compound segments being firmly bonded to each other, wherein the multi-compound comprises at least two compound layers firmly bonded to each other, wherein each compound layer is constituted of a foil compound, wherein each foil compound comprises at least two ribbon-like soft-magnetic foils having an amorphous and/or nanocrystalline structure made of a ferrous alloy, particularly of a FeSiB alloy, wherein the foils are firmly bonded to each other.
11. Transformer (1, 29, 37) according to claim 10, characterized in that the compound layers each are constituted of a longitudinally separated foil compound, wherein one foil compound is longitudinally separated with respect to a cross-section width of the respective compound body at a different place than the other foil compound arranged adjacent to said foil compound.

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