JP2010263233A - Transformer - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a transformer having a wound core whose junction structure enhances iron core characteristics by improving a magnetic flux distribution inside the iron core. <P>SOLUTION: The transformer 1 includes the annularly formed wound core 3 by laminating two or more layers of a plate magnetic material and an excitation coil 2. In the wound core 3, two or more layers of a unit are laminated and annularly-formed, the unit being composed of a plurality of layers of junction portions of the layer, in which both end portions of a plate magnetic material B are overlapped and wound so as to be the junction portion, by shifting in the winding direction against the junction portion of the adjoining layer. The width of the winding direction in the overlap width L of both end portions of the plate magnetic material of each layer is almost the same length in the same unit layer, is made to be minimum in the innermost unit, and is made to increase in each unit each time lamination takes place toward the outermost unit. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a transformer having a wound iron core in which a magnetic material is wound in multiple layers, and more particularly to a structure of a joint portion of an iron core.

  As conventional techniques related to the present invention, there are, for example, Patent Documents 1 to 3. Patent Document 1 describes a manufacturing method of a wound core using an amorphous alloy (amorphous) ribbon and a technique related to a joining structure, and Patent Document 2 discloses a wound core using an amorphous alloy (amorphous) ribbon. Describes a manufacturing method of an iron core having overlap bonding (overlap) as a basic bonding structure, and a technique related to the bonding structure. Patent Document 3 describes a technique for adjusting a distance dimension in advance in stacking.

JP-A-6-84656 JP-A-9-7849 Japanese Patent Laid-Open No. 11-8147

  In the conventional wound iron core, the magnetic flux density is high inside the iron core due to the difference in the inner and outer magnetic path lengths of the iron core material, and the magnetic flux density decreases toward the outer peripheral side. For this reason, a distortion of the magnetic flux waveform due to the magnetic flux concentration occurs, an abnormal loss occurs, and the characteristics are deteriorated.

  An object of the present invention is to improve the magnetic flux distribution inside the iron core, and to provide a transformer with improved iron core characteristics.

  In the present invention, every time each unit (or layer) of the wound core is laminated, the overlap margin of the joint portion is increased, so that the magnetic resistance on the outer peripheral side is lower than that of the conventional wound core, and the inner and outer circumferences of the iron core are reduced. The difference in magnetic flux density can be reduced.

  That is, the present invention provides a transformer including a wound iron core and an exciting coil formed by laminating a plurality of plate-like magnetic materials and forming an annular shape, and the wound iron core is formed by joining both ends of the plate-like magnetic material to each other. Two or more units formed by laminating a plurality of laminated layers by shifting the joining portions of layers wound in the winding direction with respect to the joining portions of adjacent layers are formed into an annular shape, and the plate-like magnetic material of each layer is formed. The width in the winding direction of the overlap margin at both ends is almost the same length in the layer of the same unit, and is minimized in the innermost unit, and each time the layers are laminated toward the outermost unit, It is increased by a unit, and the wound iron core is a transformer characterized in that the joint portion is outside or inside the frame of the exciting coil and is an inner iron type or an outer iron type.

  In the present invention, the wound iron core is a transformer in which the joint portion is outside the frame of the exciting coil and has an inner iron shape.

  Further, according to the present invention, the wound iron core is a transformer in which a joint portion is in a frame of an exciting coil and has an inner iron shape.

  In the present invention, the wound iron core is a transformer in which the joint portion is outside the frame of the exciting coil and has an outer iron shape.

  In the present invention, the wound iron core is a transformer having a joint portion in the frame of the exciting coil and having an outer iron shape.

  Further, according to the present invention, the wound iron core is part of a plurality of joint portions outside the excitation coil frame, the remaining joint portions are within the excitation coil frame, and is of the outer iron type. It is a transformer.

  According to the present invention, it is possible to obtain a transformer that improves the iron core characteristics by suppressing the distortion of the magnetic flux waveform due to the magnetic flux concentration by making the magnetic resistance in the iron core uniform using the above means.

The figure which shows the structure of the transformer of Example 1. FIG. The figure which shows the wound iron core junction structure of the transformer of Example 1. FIG. The figure which shows the wound iron core junction structure of the transformer of Example 2. FIG. The figure which shows the wound iron core of the transformer of a prior art. The figure showing magnetic flux density distribution inside Examples 1 and 2 and the wound core of a prior art transformer. The figure which shows the structure of the transformer of Example 3. FIG. The figure which shows the structure of the transformer of Example 4. FIG. The figure which shows the structure of the transformer of Example 5. FIG. The figure which shows the structure of the transformer of Example 6. FIG. The figure which shows the structure of the transformer of Example 7. FIG.

  The best mode for carrying out the present invention will be described. Hereinafter, embodiments of the transformer of the present invention will be described with reference to the drawings.

Example 1 will be described. FIG. 1 is a configuration diagram of a transformer according to a first embodiment of the present invention, and FIG. 2 is a cross-sectional configuration diagram of a joint portion of an iron core used in the transformer according to the first embodiment. In FIG. 1, 1 is a transformer of the first embodiment, 2 is an exciting coil for forming an electric circuit, 3 is a wound iron core for forming a magnetic circuit, and 4 is a container for mechanically protecting the transformer. is there. The iron core 3 is formed by, for example, laminating a plurality of plate-like magnetic materials of about 0.02 × 10 ⁻³ m to 0.60 × 10 ⁻³ m in a ring shape. A plate-like magnetic material laminated in a plurality of layers is deformed into a U shape, and both ends thereof are overlapped to form an annular shape.

2, 3 wound _cores, B _1, B 2 · · · · _{B N} is the layer according to the plate-shaped magnetic member constituting the wound _{core, U 1, U 2 ··· U} N is the end of the layer _{B N} unit formed by stacking while shifting in the direction of winding the, L _N is the length in the winding direction in which both end portions of the layer B _N at the junction of the winding core 3 overlap each other (overlapping margin). However, N means being arranged Nth (N = 1, 2, 3,...) From the innermost peripheral side of the wound core.

In this embodiment, the overlapping generations L _N layer B _N at the junction portion of the wound core C has the structure that increases the length of the winding direction in every layer B _N are stacked (L N _<L N + ₁ ). The overlap margin _LN increases on the outer peripheral side with respect to the stacking direction of the wound core C. This joining structure can suppress an increase in magnetic resistance from the inner peripheral side toward the outer peripheral side as compared with the conventional wound core, and the magnetic flux density difference in the inner and outer peripheral differences of the wound core C is more uniform than in the past. This is a joint structure with improved core characteristics. Since the overlap margin L _{N at} both ends of the layer B _N increases toward the outer peripheral side, it is possible to suppress an increase in magnetic resistance with respect to an increase in magnetic path length on the outer peripheral side. The magnetic flux density on the outer peripheral side can be increased as compared with the iron core.

Further, although iron loss is a numerical value representing the iron core characteristics, ideally, when the joint structure of the wound iron core is joined 100% as in the above embodiment, the iron loss is minimized. However, even when other joint structures (for example, butt-step lap method or overlap method) are used in combination with the lap part, the iron loss increases, but the increasing tendency is not always proportional to the number of joints. However, since it is affected by the arrangement of the bonding structure and bonding method, preferably the bonding structure shown in the first embodiment can be taken for more than 1/2 of the total number of bondings, for example, some overlapping Regarding the cost, L _N = L _{N + 1} may be used. Even in this case, it has been found that the core characteristics are substantially equivalent to those of the first embodiment.

A second embodiment will be described. FIG. 3 is an explanatory view of a second embodiment of the present invention, and is a cross-sectional configuration diagram of a wound iron core 3 used in a transformer. 3, similar to FIG. 2, 3 wound _{cores, B 1, B 2 ···· B} N is the layer according to the plate-shaped magnetic member constituting the wound _{core, U 1, U 2 ···· U} N is unit layer B _N are formed gradually stacked while being shifted in the direction of winding, L _N is the length in the winding direction having both ends overlap each other layer B _N at the junction of the winding core C. However, N means being arranged Nth (N = 1, 2, 3,...) From the innermost peripheral side of the wound core.

The wound iron core 3 of Example 2 is formed by laminating a plurality of layers of a plate-like magnetic material layer having a composite structure in which, for example, one to several tens of plate-like magnetic materials having a thickness of about 20 μm to 300 μm are stacked. Become. In the plate-shaped magnetic member stacked in a plurality of layers, the layer B _N at the junction is made annularly both ends thereof Kasaneawashi each other.

In Example 2, the length L _N overlap in the winding direction of the both end portions of the layer B _N, in the same unit U _N, have substantially the same overlapping generations L _N, the layer of the outer peripheral side from the inner peripheral side As shown, a structure in which the overlap margin _LN increases is shown. As the overlap margin _LN increases from the inner circumference to the outer circumference, the increase in magnetic resistance on the outer circumference side in the stacking direction is suppressed compared to the conventional wound iron core, thereby reducing the magnetic flux density difference between the inner and outer circumference differences of the iron core. Can be made more uniform than conventional wound cores, improving the average magnetic flux density of the entire wound core, improving the core characteristics and minimizing the amount of magnetic material used. It is a joint structure that can realize efficiency.

In Example 2, the overlap margin _LN increases from the inner periphery to the outer periphery, so that an increase in magnetic resistance on the outer periphery side in the stacking direction is suppressed as compared with the conventional wound core, and the magnetic flux due to the difference between the inner and outer periphery of the iron core is suppressed. The density difference is more uniform than the conventional wound core, and the average magnetic flux density of the entire wound core can be improved. As a result, it is a joining structure that can improve the iron core characteristics, and at the same time, by arranging the overlapping margin _LN in the same unit, minimizing the amount of magnetic material used and realizing the efficiency of the joining operation. In the second embodiment, similarly to the first embodiment, it is desirable that 1/2 or more of the total number of junctions be the junction of the above-described embodiment.

In the first and second embodiments, the overlap margin L _N of the first layer B _N is optimally about 1 mm ≦ L _N ≦ 250 mm with respect to the transformer capacity of 5 kVA to 2000 kVA. Although it is ideal that the overlap margin L ₁ = 0 in the first innermost layer B ₁ is considered, L ₁ is preferably ₁ mm or more in consideration of an actual manufacturing process and manufacturing accuracy. Also, if the transformer capacity increases wound core itself becomes large, L _n the outermost side ratio is reduced relative to the magnetic path length at the outermost side, the effect of a uniform magnetic flux density difference comes faded. For this reason, in consideration of practical workability and cost balance, it is preferable to suppress L _n on the outermost peripheral side to about 250 mm.

  FIG. 5 is an explanatory diagram of magnetic flux distribution in the wound cores of Examples 1 and 2 and the prior art. In FIG. 5, A is the magnetic flux distribution characteristic in the wound core 3 of Example 1 (see FIG. 2), and B is the magnetic flux distribution characteristic in the wound core 3 of Example 2 (see FIG. 3). C shows the magnetic flux distribution characteristics of the AA ′ portion in the wound core of the prior art (see FIG. 4). In the wound cores of Examples 1 and 2, the increase in the magnetic resistance is mitigated, and the magnetic flux density on the outer peripheral side can be kept high as in the characteristics A and B. For this reason, the magnetic flux density distribution in the iron core is more uniform than that of the conventional wound core, and the core characteristics can be improved. In the wound core of Example 1, the increase in magnetic resistance is mitigated, and the average magnetic flux density is increased as shown in characteristic (b). Therefore, the magnetic flux density distribution in the iron core is more uniform than that of the conventional wound core. As a result, the core properties are improved. The characteristic b of the wound core of Example 2 is lower in magnetic flux density on the outer peripheral side than that of the wound core of Example 1, but the cutting length (usage) of the magnetic material can be minimized. And the joining work is the easiest. Therefore, according to the second embodiment, it is possible to improve the magnetic flux distribution in the iron core and improve the efficiency of the iron core manufacturing work.

  A third embodiment will be described. FIG. 6 is an explanatory diagram of the third embodiment of the present invention, showing the relationship between the wound iron core and the coils constituting the transformer of this embodiment. In FIG. 6, 5 indicates that the relationship between the coil and the iron core is an inner iron type, 2 indicates an exciting coil, 3 indicates a wound iron core, and 6 indicates a wrap portion of the wound iron core. The wound core 3 is the same as in Example 1 or 2. In Example 3, the lap portion of the iron core is arranged outside the frame of the exciting coil, so that the lap alignment work is easy, and since it is an inner iron type, the wound iron core is a single leg and requires less time for the lap alignment operation. Thus, in Example 3, the iron core characteristics can be improved and the working time can be greatly reduced.

  Example 4 will be described. FIG. 7 is an explanatory diagram of the fourth embodiment of the present invention, showing the relationship between the wound iron core and the coils constituting the transformer of this embodiment. In FIG. 7, 5 indicates that the relationship between the coil and the iron core is an inner iron type, 2 indicates an exciting coil, 3 indicates a wound iron core, and 6 indicates a wrap portion of the wound iron core. The wound core 3 is the same as in Example 1 or 2. In Example 4, the wrap portion of the wound iron core is arranged in the frame of the exciting coil. For this reason, the lapping operation becomes difficult, but the height of the iron core can be reduced by about 5%. Thus, in Example 4, the core characteristics can be improved and the transformer can be made compact.

  Example 5 will be described. FIG. 8 is an explanatory diagram of the fifth embodiment of the present invention, and shows the relationship between the wound core and the coil constituting the transformer of this embodiment. In FIG. 8, 7 indicates that the relationship between the coil and the iron core is an outer iron type, 2 indicates an exciting coil, 3 indicates a wound iron core, and 6 indicates a wrap portion of the wound iron core. The wound core 3 is the same as in Example 1 or 2. In Example 5, the wrap portion of the iron core is arranged outside the frame of the exciting coil. For this reason, the lapping work is easy and the effect of reducing the working time is great.

  Example 6 will be described. FIG. 9 is an explanatory diagram of the sixth embodiment of the present invention, showing the relationship between the wound iron core and the coils constituting the transformer of the present embodiment. In FIG. 9, 7 indicates that the relationship between the coil and the iron core is an outer iron type, 2 indicates an exciting coil, 3 indicates a wound iron core, and 6 indicates a wrap portion of the wound iron core. The wound core 3 is the same as in Example 1 or 2. In Example 6, the wrap portion of the iron core is arranged in the frame of the exciting coil. For this reason, it is difficult to perform the lapping operation, but the height of the iron core can be reduced by about 5%, the iron core characteristics can be improved, and the transformer can be made compact.

  Example 7 will be described. FIG. 10 is an explanatory diagram of the seventh embodiment of the present invention, showing the relationship between the wound iron core and the coils constituting the transformer of this embodiment. In FIG. 10, 7 indicates that the relationship between the coil and the iron core is an outer iron type, 2 indicates an exciting coil, 3 indicates a wound iron core, and 6 indicates a wrap portion of the wound iron core. The wound core 3 is the same as in Example 1 or 2. FIG. 10 shows an outer iron type in which one side of the iron core joint is disposed outside the excitation coil frame and in a direction perpendicular to the winding direction, and the other iron core joint is located outside the excitation coil frame and on the side of the coil. The structure is arranged on the side. In Example 7, since all the wrap portions of the wound iron core are arranged outside the coil frame, the lap alignment work is easy.

  It is also possible to use a combination of the wound cores of Examples 1 and 2 above. For example, in Example 7, the outer iron type, one-side wound core joining structure is 1/2 as the joining structure in Example 1, 1/2 is the butt step lap system, and the other wound core joining is in Example 2. Join structure. As a result, the workability can be improved and the height dimension on one side can be reduced to optimize workability and transformer dimensions.

  As described in the above embodiments, in the present invention, by changing the ratio of the lap portion arrangement and the joint structure according to the transformer capacity and its specifications, not only the characteristics of the wound core are improved, but also the workability. It is also possible to optimize the cost by adjusting the balance between the core characteristics and the transformer dimensions.

  In the present invention, the plate-like magnetic material forming the wound iron core is not limited to an amorphous (amorphous) ribbon material, a silicon steel plate, or the like, but may be another magnetic material.

1: Transformer core 2: Excitation coil 3: Iron core 4: Container 5: Inner iron type 6: Wrap part 7: Outer iron type B _N : Layer made of plate-like magnetic material.
U _N : a unit formed by laminating a plurality of layers B _N while being shifted L _N : a length in which both end portions overlap with each other in the winding direction of the layer B _N.
A: Magnetic flux density distribution curve in the lamination direction of the iron core of Example 1.
B: Magnetic flux density distribution curve in the lamination direction of the iron core of Example 2.
C: Magnetic flux density distribution curve in the stacking direction of a conventional wound core.

Claims (1)

In a transformer including a wound core and an exciting coil formed by laminating a plurality of plate-shaped magnetic materials into an annular shape,
The wound iron core is formed by laminating a plurality of laminated portions in which the joining portions of the layers formed by winding both ends of the plate-shaped magnetic material to overlap each other in the winding direction with respect to the joining portions of the adjacent layers. Two or more units are stacked and formed into an annular shape,
The width in the winding direction of the overlap margin at both ends of the plate-like magnetic material of each layer is almost the same length in the layer of the same unit, and is the smallest in the innermost unit, and in the outermost unit Increase each unit as you stack,
The wound iron core has a junction part outside or inside the frame of the exciting coil, and is an inner iron type or an outer iron type.

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