EP4182958B1 - Verfahren zur herstellung von schleifen für einen magnetkreis - Google Patents

Verfahren zur herstellung von schleifen für einen magnetkreis Download PDF

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Publication number
EP4182958B1
EP4182958B1 EP21746528.5A EP21746528A EP4182958B1 EP 4182958 B1 EP4182958 B1 EP 4182958B1 EP 21746528 A EP21746528 A EP 21746528A EP 4182958 B1 EP4182958 B1 EP 4182958B1
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EP
European Patent Office
Prior art keywords
roll
loops
mandrel
manufacturing
rewinding
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EP21746528.5A
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English (en)
French (fr)
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EP4182958A1 (de
Inventor
Edouard Bonnefous
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Safran Electrical and Power SAS
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Safran Electrical and Power SAS
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Publication of EP4182958A1 publication Critical patent/EP4182958A1/de
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—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 for manufacturing coils
    • H01F41/10—Connecting leads to windings
    • 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
    • H01F41/0233—Manufacturing of magnetic circuits made from sheets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F30/00—Fixed transformers not covered by group H01F19/00
    • H01F30/06—Fixed transformers not covered by group H01F19/00 characterised by the structure
    • H01F30/12—Two-phase, three-phase or polyphase transformers

Definitions

  • the invention relates to magnetic circuits for magnetic induction devices, such as three-phase power transformers, and more particularly relates to a method of manufacturing loops constituting such magnetic circuits.
  • a power transformer includes a magnetic circuit, commonly called a core, along with coil blocks placed around this magnetic circuit to provide inductive coupling.
  • the magnetic circuit 2 of a three-phase transformer 1 can in a known manner be in the form of a three-dimensional prismatic cage, being formed from the association of three loops 3 which are juxtaposed two by two extending relatively from each other at an angle of 60°, triangularly.
  • These loops 3 are of prismatic shape, namely each have a generally rectangular outline, and are shaped so as to each present an oblique junction surface 4 extending at an angle value of 30° relative to the plane of extent of the corresponding loop.
  • the loops 3 form two by two, at their junction, the columns 6 of the magnetic circuit 2 around each of which is placed a block of coils 7.
  • the assembly of the blocks of coils leads to splitting each loop 3 into two half-loops taking the shape of the letter U and each comprising two cutting faces, which are then generally reconstituted through the coil blocks while maintaining the cutting faces facing each other.
  • Loops 3 are usually manufactured by stacking layers of magnetic material.
  • One of the methods used by manufacturers to obtain such a stack of layers consists of winding a strip of magnetic strip around a mandrel with a rectangular section.
  • a first method known from the state of the art consists of adjusting, upstream of the winding around the mandrel to rectangular section, the width of the strip by means of laser cutting.
  • this method reveals in practice the appearance of burrs, namely irregularly formed excess material, along the cutting edge, which are sources of short circuits and undesirable spaces between the layers once winding done.
  • An alternative method to pre-cutting the strap illustrated on the figure 2 , consists of winding a strip of magnetic strip 8 of constant width around a mandrel with a rectangular section, then chamfering the edges, marked with H, by machining, electroerosion, or even cutting by water jet.
  • This method makes it possible to overcome the surface defects noted in the case of laser cutting of the strip, but nevertheless still induces waste of expensive materials in the same way. This method, which both generates losses and is time-consuming, therefore appears to be perfectible.
  • the patent EP001 0427 A1 discloses the formation of magnetic core loops of a three-phase delta core by windings of magnetic ribbons of decreasing width derived in a complementary manner from a stock ribbon, combined with the winding of an uncut stock ribbon.
  • the aim of the invention is therefore to propose a solution for the manufacture of magnetic circuit loops making it possible to limit the waste of material and overall production costs.
  • the invention also relates to a method of manufacturing loops thus defined, in which the bringing into conformity c) of the first and second half-rollers comprises a sub-step of straightening a convex appearing at the end of the step of unwinding and rewinding in reverse of the second half-roll on the mandrel, this convexity corresponding to the contour of the delimitation surface at the end of the sub-step of unwinding and rewinding in reverse, so as to that the orientation of the delimiting surface of the second half-roll after straightening corresponds to the orientation of the delimiting surface of the first half-roll.
  • the invention also relates to a method of manufacturing loops thus defined, comprising a sub-step of digging the delimitation surface of the second half-roll before the sub-step of unwinding and re-winding in reverse on the mandrel, this digging sub-step countering the appearance of a convexity corresponding to the contour of the delimiting surface after re-winding in reverse, so that the orientation of the delimiting surface of the second half-roll to the resulting from unwinding and re-winding in reverse on the mandrel corresponds to the contour of the boundary surface of the first half-roll.
  • the invention also relates to a method of manufacturing loops thus defined, comprising an additional shape transition step d) after the conforming step c) of the first and second half-rolls, this shape transition step d) comprising unwinding and rewinding at the location of the first half-roll and the second half-roll on another mandrel with a non-circular section.
  • the invention also relates to a method of manufacturing loops thus defined, in which the other mandrel is of generally rectangular section.
  • the invention also relates to a method of manufacturing loops thus defined, in which the mandrel is of generally rectangular section.
  • the invention also relates to a power transformer, comprising a magnetic circuit having the shape of a three-dimensional cage, this magnetic circuit being formed of a plurality of loops arranged end-to-end according to a closed contour, of which two of these loops are manufactured in accordance with the loop manufacturing process thus defined.
  • the method according to the invention is part of a desire to optimize the manufacturing of loops 3 of the magnetic circuit 2 of the figure 1 , from a strip of magnetic strip.
  • the idea underlying the invention is based on the improved compatibility of a machining operation applied to a circular contour of a part compared to an operation machining applied to a non-circular contour, such as the rectangular contour of loops 3.
  • the method of manufacturing loops 3 begins with a step A of forming a roll with a cylindrical section/contour, marked by 11 on the Figure 3 , by winding around a first mandrel 12, of circular section and longitudinal axis X, a strip of magnetic strip 13 having dimensions of constant thickness and width.
  • the roller 11 is held on either side of its longitudinal ends by jaws with a concentric clamping function on a part holder of the parallel lathe, the assembly driven in rotation by a spindle, the longitudinal axis roller corresponding to the axis of rotation of the spindle.
  • This cutting step B consists, when the roller 11 is rotated around its longitudinal axis by 17 on the Figure 4 .
  • the cutting tool moves in a rectilinear manner along a driving direction Y extending at an angle ⁇ relative to this longitudinal axis -rollers 14, 16 of respective longitudinal axis X14, X16.
  • the invention advantageously provides for driving the roller 11 in the direction of rotation which tends to tighten the spiral formed by the winding of the strip of magnetic strip 13, so as to avoid deformation of the strip during cutting. .
  • each of the two half-rollers 14, 16 obtained comprises a respective delimitation surface, denoted 14a, 16a, which is formed by the tool to be cut, as illustrated in the figure 4 .
  • These delimiting surfaces 14a, 16a are frustoconical and extend at an angle equivalent to the overall plane of the corresponding half-roller 14, 16.
  • the first half-roll 14 has a delimitation surface 14a called “external” or “outgoing” in that any normal vector V14 to this surface does not meet the longitudinal axis X14; while the delimitation surface 16a of the second half-roll 16, of opposite orientation, is said to be “interior” or “re-entrant” in that any normal vector V16 to this surface meets the longitudinal axis X16.
  • the cutting step B is carried out so that the longitudinal extents of the first half-roll 14 measured at its interior periphery and its exterior periphery correspond respectively to the longitudinal extents of the second half-roll 16 at its periphery. exterior and its interior periphery.
  • the cross section of the second half-roll 16 corresponds to the cross section of the first half-roll 14 inverted post-cutting.
  • This cutting step B simple to carry out and specifically adapted for the machining of parts with a circular contour, makes it possible to form frustoconical delimitation surfaces 14a, 16a intended to each become the oblique junction surfaces 4 of the loops 3 with a rectangular contour of there figure 1 .
  • the first and second half-rollers 14, 16 need to be shaped to conform to the architecture of the loops 3.
  • the first half-roller 14 has a cross-section which corresponds to the cross-section of a loop 3 as illustrated in Fig. figure 1 , particularly with regard to its delimitation surface 14a, but has a circular contour, namely which differs from the expected rectangular contour.
  • the work on the first half-roller 14, to constitute a loop 3 consists of a single transition in shape, going from a circular contour to a rectangular contour.
  • the invention provides a section transition step so as to make the second half-roll 16 identical to the first half-roll 14 in its post-cutting state, this before carrying out a shape transition step to obtain a second loop 3.
  • This section transition step is established in two successive substeps, denoted C2 and D2.
  • the first sub-step C2 consists of unwinding the second half-roll 16 by simultaneously rewinding it upside down around a third mandrel 18 with a circular outline and of diameter equivalent to the first mandrel 12 used to form the roll 11 .
  • this first sub-step C2 does not make it possible to find the section of the first half-roller 14, which is what the second sub-step D2 aims to correct.
  • This second sub-step D2 consists of a straightening operation of the convex K, advantageously carried out with a parallel lathe and an envelope working tool 19 which moves linearly along an inclined plane following the angle ⁇ relative to the axis of the half-roller 16'. The removal of this curved K leads to making the second half-roll, denoted 16" at this stage, substantially conforming to the first half-roll 14.
  • step C1 the following step of shaping the second half-roll corresponds to step C1 described to obtain a loop 3, namely consists of a shape transition by re-winding right side up on the second mandrel 15 of generally rectangular section.
  • This first embodiment provides for removing by machining the curved K which appears, due to the frustoconical nature of the delimitation surface 16a, after re-winding in reverse (sub-steps C2 and D2).
  • the method aims to counter the appearance of the convex K by hollowing out the delimitation surface 16a of the second half-roller 16, so that a reverse rewinding generates a surface with generator substantially rectilinear, and not convex.
  • this second embodiment of the method differs from the first embodiment with regard to the shaping of the second half-roll 16.
  • the shaping of the second half-roll 16 according to the second embodiment is ensured in two successive stages.
  • the first step which consists of digging the delimitation surface 16a to generate a counter-convexity, is advantageously carried out by straightening with a parallel lathe which introduces a rotation of the second half-roller 16 around its axis envelope work 20 which moves along a curve to machine.
  • the second step F consists of unrolling the second half-roll, denoted 16′′′ at the end of the first step E, by simultaneously rewinding it upside down around the second mandrel 15 with a generally rectangular section as described above.
  • the trajectory of the tool 20 is controlled so that the counter-convex surface resulting from its passage, denoted 16a′′′, counterbalances the difference in length of initial magnetic strip strip 13 as described on the basis of the Figure 7 .
  • the second half-roll generally corresponds to a loop 3 as shown in figure 1 , including in particular a surface with a substantially rectilinear generatrix denoted R, but is nevertheless distinguished locally by a junction surface which is crenellated, not smooth.
  • This identified particularity results from the inversion of the cutting angle of the layers of magnetic strip 13 after rewinding in reverse, leading to the appearance of J streaks.
  • the cutting tool, marked 21 differs from the tool 20 used in the case of cutting step B as illustrated, with regard to its head, that is to say from its active part to cutting the material.
  • the head of the tool 20 used in step B is in the form of a bevel which extends continuously without forming any discontinuity in the extension of the rod which supports the head, forming a point at the end d 'tool.
  • the head of the tool 21 is also in the form of a bevel extending in the extension of the rod to form a first point 21a at the end of the tool, but also projects transversely forming a second point 21b at the junction.
  • the invention judiciously provides that the machining step D2, E of the protocol considered is carried out by turning before modifying the shape of the half-roll 16 by rewinding on mandrel with generally rectangular section 15.
  • the second mandrel 15, of substantially rectangular section it is understood that as the last destination mandrel, on which the half-rollers are wound to adopt the shape of the loops 3, its perimeter must necessarily correspond to the internal circumference of loop.
  • the invention is not limited to compliance with the aforementioned diameter criterion with regard to the first and third mandrels 12 and 18, as well as the cutting angle ⁇ value, on the basis of the existence of a diameter-angle ⁇ geometric link explained below in a generic manner with reference to the figure 13 .
  • control configuration which meets the aforementioned sizing criteria.
  • This control configuration comprises a first mandrel M whose diameter corresponds to the internal circumference of a loop 3 of the figure 1 , and which carries a half-roll P resulting from cutting at an angle of 60°. By application of the process as described at this stage, this half-roll P becomes a loop as defined in figure 1 .
  • a dimension J corresponding to the distance separating the length projected on the mandrel from the delimitation surface formed by cutting.
  • a first configuration differs from the control configuration, in that it presents a mandrel M1, of diameter greater than the control mandrel M, which carries a half-roller P1 formed of a strip of length equivalent to that used in the control configuration ( considering the fall of material after cutting), to present a strip volume equivalent to the control half-roll P. It is possible to achieve the formation of a loop 3 according to the figure 1 by application of the process, using a cutting angle ⁇ 1 which is less than 60° and which is defined so as to respect dimension J.
  • a second configuration differs from the control configuration in that it presents a mandrel M2, this time with a diameter smaller than the control mandrel M, which carries a half-roller P2 formed of a strip of length equivalent to that used in the control configuration . It is also possible to achieve the formation of a loop 3 according to the figure 1 by application of the method according to the invention using a cutting angle ⁇ 2 which is greater than 60° and which is defined so as to respect the dimension J.
  • process according to the invention is not limited to the production of loops adopting the particular morphology of the figure 1 .
  • the method according to the invention is not limited to the production of loops having junction surfaces extending at an angle of 30° relative to the loop plane, by defining the angle ⁇ just needed.
  • any type of shape of loops 3 can be considered in practice without departing from the scope of the invention.
  • the invention provides for the possibility of enriching the process by additional machining operations which are advantageously carried out in turning, for example by turning and straightening, such as to delimit for example corner surfaces identified by 14b, 16b in the example of figures 4 and 5 , also visible on the figure 1 but not referenced.
  • the corner surface denoted 14b can be erected easily in step B.
  • the corner surface denoted 16b can be erected easily in step D2, but also erected more difficult in step B or E, with a counter-bulged. This counter-bulging is not essential in the case of the formation of the corner surface denoted 14b, because it is less pronounced and external in the assembly of the magnetic circuit 1 of the figure 1 .
  • the invention has been described in the case where the roll 11, made from the strip of magnetic strip 13, is split into two half-rolls 14, 16 of the same volume.
  • the width and length of the strip of magnetic strip 13 used to form the roller 11 are defined with regard to the dimensions of the loops to be manufactured.
  • a three-phase transformer includes three loops, it can be considered to dimension the roller 11 so as to be able to judiciously extract several pairs each formed of a first and second half-rollers complementary 14, 16.
  • the application of the method according to the invention makes it possible to limit manufacturing costs when it is desired to manufacture at least two loops.

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

Claims (10)

  1. Verfahren zur Herstellung von Schleifen (3) eines magnetischen Kreises (2) für einen Mehrphasentransformator (1), ausgehend von einem Magnetband (13), wobei das Verfahren gekennzeichnet ist durch mindestens die Schritte:
    a) Bereitstellen eines Magnetbandes (13) konstanter Breite in Form einer zylindrischen Walze (11), die sich entlang einer Längsachse (X) erstreckt;
    b) Schneiden der Walze (11), um eine erste und eine zweite Walzenhälfte (14; 16) der Längsachse (X14; X16) zu erhalten, die jeweils eine jeweilige Begrenzungsfläche (14a; 16a) umfassen, die nach dem Abschluss ihrer Trennung von der anderen Walzenhälfte (14; 16) gebildet wird, wobei das Schneiden schräg zur Längsachse (X) erfolgt, so dass die Ausrichtung der Begrenzungsflächen (14a; 16a) entgegengesetzt ist: die erste Walzenhälfte (14) umfasst eine Begrenzungsfläche (14a), die nach außen in Bezug zu ihrer Längsachse (X14) ausgerichtet ist, während die zweite Walzenhälfte (16) eine Begrenzungsfläche (16a) umfasst, die nach innen in Bezug zu ihrer Längsachse (X16) ausgerichtet ist;
    c) Übereinstimmen der ersten und der zweiten Walzenhälfte (14, 16), um zwei Schleifen (3) zu fertigen, das mindestens einen Teilschritt des umgekehrten Abwickelns und Wieder-Aufwickelns der zweite Walzenhälfte auf einen Dorn (15, 18) einschließt.
  2. Verfahren zur Herstellung von Schleifen nach Anspruch 1, wobei das Übereinstimmen c) der ersten und zweiten Walzenhälfte (14, 16) einen Teilschritt zum Abrichten einer Wölbung (K) umfasst, die am Abschluss des Schritts des umgekehrten Abwickelns und Wieder-Aufwickelns der zweiten Walzenhälfte (16) auf einen Dorn (18) auftritt, wobei diese Wölbung (K) der Kontur der Begrenzungsfläche (16a) am Abschluss des Teilschritts des umgekehrten Abwickelns und Wieder-Aufwickelns entspricht, so dass die Ausrichtung der Begrenzungsfläche (16a) der zweiten Walzenhälfte (16) nach dem Abrichten der Ausrichtung der Begrenzungsfläche (14a) der ersten Walzenhälfte (14) entspricht.
  3. Verfahren zur Herstellung von Schleifen nach Anspruch 1, einen Teilschritt umfassend des Vertiefens der Begrenzungsfläche (16a) der zweiten Walzenhälfte (16) vor dem Teilschritt des umgekehrten Abwickelns und Wieder-Aufwickelns auf den Dorn (15), wobei dieser Teilschritt des Vertiefens dem Auftreten einer Wölbung (K) entgegenwirkt, die der Kontur der Begrenzungsfläche (16a) nach dem umgekehrten Wieder-Aufwickeln entspricht, so dass die Ausrichtung der Begrenzungsfläche (16a) der zweiten Walzenhälfte (16) am Abschluss des umgekehrten Abwickelns und Wieder-Aufwickelns auf den Dorn (15) der Kontur der Begrenzungsfläche (14a) der ersten Walzenhälfte (14) entspricht.
  4. Verfahren zur Herstellung von Schleifen nach Anspruch 2, einen zusätzlichen Schritt des Transition der Form d) nach dem Schritt des Übereinstimmens c) der ersten und zweiten Walzenhälfte (14, 16) umfassend, wobei dieser Schritt des Transition der Form d) ein Abwickeln und Wieder-Aufwickeln an der Stelle der ersten Walzenhälfte und der zweiten Walzenhälfte auf einem anderen Dorn (15) mit nicht kreisförmigem Querschnitt umfasst.
  5. Verfahren zur Herstellung von Schleifen nach Anspruch 4, wobei der andere Dorn (15) einen insgesamt rechteckigen Querschnitt hat.
  6. Verfahren zur Herstellung von Schleifen nach Anspruch 3,
    wobei der Dorn (15) einen nicht kreisförmigen Querschnitt hat; und
    wobei der Schritt des Übereinstimmens c) der ersten und zweiten Walzenhälfte (14, 16) einen Teilschritt des Abwickelns und Wieder-Aufwickelns an der Stelle der ersten Walzenhälfte (14) auf den Dorn (15) umfasst.
  7. Verfahren zur Herstellung von Schleifen nach Anspruch 6, wobei der Dorn (15) einen insgesamt rechteckigen Querschnitt hat.
  8. Verfahren zur Herstellung von Schleifen nach einem der vorhergehenden Ansprüche, wobei die Schleifen von prismatischer Form sind, und die Schleifen eine insgesamt rechteckige Kontur aufweisen.
  9. Verfahren zur Herstellung eines magnetischen Kreises (2) für einen Mehrphasentransformator (1), umfassend:
    - Erstellen von mindestens drei Schleifen (3) mit dem Verfahren nach einem der Ansprüche 1 bis 8,
    - die Anordnung Ende-an-Ende der Schleifen (3), um eine geschlossene Kontur zu bilden.
  10. Verfahren zur Herstellung eines Leistungstransformators (1), wobei der Leistungstransformator (1) einen magnetischen Kreis (2) umfasst, der die Form eines dreidimensionalen Käfigs aufweist, wobei dieser magnetische Kreis aus einer Vielzahl von Schleifen (3) gebildet ist, die Ende-an-Ende in einer geschlossenen Kontur angeordnet sind, wobei mindestens zwei der Schleifen (3) des Leistungstransformators (1) gemäß dem Herstellungsverfahren nach einem der Ansprüche 1 bis 8 hergestellt sind.
EP21746528.5A 2020-07-20 2021-07-08 Verfahren zur herstellung von schleifen für einen magnetkreis Active EP4182958B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR2007578A FR3112648B1 (fr) 2020-07-20 2020-07-20 Procédé de fabrication de boucles pour circuit magnétique
PCT/FR2021/051262 WO2022018344A1 (fr) 2020-07-20 2021-07-08 Procédé de fabrication de boucles pour circuit magnétique

Publications (2)

Publication Number Publication Date
EP4182958A1 EP4182958A1 (de) 2023-05-24
EP4182958B1 true EP4182958B1 (de) 2024-03-06

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EP21746528.5A Active EP4182958B1 (de) 2020-07-20 2021-07-08 Verfahren zur herstellung von schleifen für einen magnetkreis

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US (1) US20230282416A1 (de)
EP (1) EP4182958B1 (de)
CN (1) CN116137925A (de)
FR (1) FR3112648B1 (de)
WO (1) WO2022018344A1 (de)

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NZ191840A (en) * 1978-10-19 1983-06-14 L Manderson Transformer core construction
ES2406808T3 (es) * 2010-06-08 2013-06-10 Abb Technology Ag Método para la fabricación de núcleos de transformador triangular fabricados de metal amorfo
IL217576A0 (en) * 2012-01-17 2012-03-29 Eliezer Adar Three phase transformer and method for manufacturing same
US8729998B2 (en) * 2012-06-06 2014-05-20 Abb Technology Three-step core for a non-linear transformer

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FR3112648B1 (fr) 2023-04-14
WO2022018344A1 (fr) 2022-01-27
FR3112648A1 (fr) 2022-01-21
US20230282416A1 (en) 2023-09-07
EP4182958A1 (de) 2023-05-24
CN116137925A (zh) 2023-05-19

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