JP2012134448A - Reactor device using amorphous material and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve such a problem that it is difficult to manufacture a large capacity reactor device because the core material of a reactor device, i.e. an amorphous material, has poor workability when compared with a silicon steel plate used similarly, and iron loss of which deteriorates significantly due to processing stress, and to propose a manufacturing method and the shape of a core for a reactor suitable for the amorphous material.SOLUTION: When a core is manufactured, a wound core unit split into a plurality of sections is manufactured previously and assembled. Stress deterioration of the amorphous material is limited by not hardening the core with resin and the connection is brought to the R portion of the core. Since cross-sectional area of the connection is increased, flux density is limited and fringing phenomenon occurring at the connection can be suppressed.

Description

  The present invention relates to a reactor device using an amorphous material (amorphous material) and a method for manufacturing the reactor, and in particular, a plurality of laminated amorphous materials (amorphous materials) obtained by laminating a plurality of amorphous ribbon materials cut to a predetermined length. The present invention relates to a reactor device in which stacked core units are abutted at a plurality of unit abutting joints, and a manufacturing method thereof.

  Prior art related to the present invention, which is described in the patent document, for example, relates to a reactor made of a magnetic ribbon, but is described in Japanese Patent Laid-Open No. 2006-100513 (Patent Document 1). There is technology. An invention is disclosed in which an object of the present invention is to significantly reduce eddy current loss due to leakage magnetic flux, and to provide a reactor using a low-cost core that can be easily manufactured with less man-hours. This is because, in a reactor consisting of a yoke core made of a wound core formed by winding a magnetic ribbon, a leg core made of a laminated core punched and laminated with a magnetic ribbon, and a coil, the laminated surface of the leg iron core is the joint. The present invention relates to a reactor characterized by having an arrangement perpendicular to the laminated surface of the iron core.

  Japanese Patent Application Laid-Open No. 6-292326 (Patent Document 2) discloses an invention for the purpose of supplying a reset current to a magnetic switch with a high inductance and reducing the size of the device. Thereby, in the DC power supply for initial state setting that DC magnetizes the magnetic circuit of the magnetic switch in one direction by supplying a DC current from the DC power supply to the reset winding of the magnetic switch that becomes a saturable reactor or a saturable transformer, Both ends of the pair of amorphous cut cores are supported by a support plate so that there is a gap, and a coil is applied from above to form a DC reactor, and this DC reactor is inserted between the DC power supply and the reset coil to provide a magnetic switch. The leakage current from the power supply to the DC power supply is suppressed with high inductance. By using a core with a gap, a reset current is supplied without causing magnetic saturation, and miniaturization is achieved by using an amorphous core.

  Furthermore, Japanese Patent Application Laid-Open No. 62-92307 (Patent Document 3) discloses a method for producing a static induction electric appliance using a wound iron core made of an amorphous magnetic alloy ribbon, and the amorphous magnetic alloy thin film is disclosed. A step of forming a wound body by winding a band, cutting two portions of the wound body and developing the laminated body, and laminating the amorphous magnetic alloy thin ribbon with one end aligned. And a step of dividing the two sets of laminated blocks formed in this step into a plurality of unit blocks, each having a plurality of units, and two U-shaped winding frame structures, one winding frame structure The unit blocks of the one laminated block are alternately laminated in the length direction to form a U-shape, and the other laminated block is alternately arranged in the length direction on the other winding frame structure. Laminate in a different direction and mold it into a U shape. And a step of annealing the two sets of laminated blocks having a U-shape, and a step of inserting the two sets of laminated blocks having a U-shape into a winding and abutting both ends thereof. A method for manufacturing a static induction device is disclosed.

  Japanese Patent Application Laid-Open No. 62-265711 (Patent Document 4) also discloses that a first iron core is manufactured by cutting an amorphous magnetic alloy strip at one location after winding and then forming it into a U shape. After winding the crystalline magnetic alloy strip to a diameter smaller than the winding diameter when the first iron core is manufactured, it is cut at one place and then formed into a linear shape to form the second iron core, Disclosed is a method for manufacturing a transformer, wherein a wound core is formed by joining a joint surface at both ends of the first iron core and a joint surface at both ends of the second iron core after inserting a coil into the iron core. Yes.

Japanese Patent Application Laid-Open No. 61-180408 (Patent Document 5) discloses a laminated block in which a large number of amorphous magnetic alloy ribbons are laminated to form a U shape and an end surface forms an inclined surface. A wound iron core formed by laminating amorphous magnetic alloy ribbons to form a U-shaped laminated block whose end face is an inclined surface that forms a pair with the end face of the laminated block, but by combining the end faces with each other; And a coil mounted on the wound iron core.
The patent document 5 describes in the specification that “first, as shown in FIG. 3, the amorphous magnetic alloy ribbon 13 is wound, and a part of the wound body is cut along the line AA. It is premised that a cut core is formed by cutting a wound iron core as described in “Responsible relative 18 formed by laminating a large number of amorphous magnetic alloy ribbons 13 that gradually increase”. Technology.

  In JP-A-61-180411 (Patent Document 6), a large number of amorphous magnetic alloy ribbons forming each turn of a wound iron core are laminated with their positions shifted in the length direction. Forming a laminated block in which an end face of the end portion forms an inclined surface, and fixing the end portion having the inclined end face, bending the laminated block along a length direction, and inclining the other end portion of the laminated block The manufacturing method of the wound core structure characterized by comprising the process made into a surface is disclosed. This Patent Document 6 is also a technique based on a cut core obtained by cutting a wound iron core.

  Japanese Patent Application Laid-Open No. 60-86813 (Patent Document 7) discloses a method of manufacturing a cut core by combining two unit cut cores having a U-shape, and the unit cut core includes a plurality of amorphous magnetic cores. A step of cutting the alloy ribbons to a predetermined length, and aligning the cut end faces of the amorphous magnetic alloy ribbons with a magnet and aligning the amorphous magnetic alloy ribbons along the cored bar Bending into a U-shape and fixing to the metal core, a process of annealing in a magnetic field with the amorphous magnetic alloy ribbon group fixed to the metal core, and the amorphous magnetic alloy after annealing. A method for producing a cut core, comprising: a step of winding a tape around the amorphous magnetic alloy ribbon group in a state where the ribbon group is removed from the core metal and the cut end face is attracted and fixed to a magnet. It is disclosed.

JP 2006-100513 A JP-A-6-292326 JP-A-62-92307 JP-A-62-265711 JP 61-180408 A Japanese Patent Laid-Open No. 61-180411 JP 60-86813 A

  Amorphous materials with low loss characteristics compared to electrical steel sheets used for the same reactor core have high hardness and are difficult to process. At present, as a method of manufacturing an iron core for a reactor using an amorphous material, an iron core such as a cut core and a core with a gap is once formed and solidified with a resin, and then a cross section is cut. This cutting method has been conventionally performed by cutting with a diamond cutter or a grindstone, and in order to fix the iron core, the iron core is hardened with a resin in order to prevent the iron core from being rusted by cooling water. This operation is not a problem if the reactor has a small capacity including cutting, but the difficulty and the processing cost increase as the size increases. The inventor of the present application tried water jet processing, wire cut processing, and laser processing as cutting methods of the iron core, but none of them was suitable for cutting an amorphous iron core having a large cross section.

  Moreover, although it is a gap part of the reactor core of a cut part, the gap part of an iron core is an important part for the reactor characteristic of adjusting the magnetic characteristic by increase in iron loss by fringing and adjusting the gap width for the reactor. However, the conventional cutting method has a problem that the degree of freedom in the shape of the gap portion is low, so that an optimum structure cannot be obtained.

  Furthermore, the amorphous material itself is also a material that is weak against processing stress, and iron loss is greatly deteriorated by applying processing such as fixing and cutting of the iron core with a resin or the like. Since the iron core is hardened with a resin and then cut, it is impossible to remove stress applied during cutting.

  As described above, there is a limit in the conventional processing method for increasing the size and efficiency of the reactor device using the amorphous material, and it is desired to establish a new manufacturing method of the reactor using the amorphous material. .

  On the other hand, Patent Document 7 (Japanese Patent Application Laid-Open No. 60-86813) discloses a technique for obtaining a cut core by cutting a plurality of amorphous magnetic alloy ribbons into predetermined lengths. Yes. However, in the technique described in Patent Document 7, the cut amorphous magnetic alloy ribbons are formed by laminating the cut amorphous magnetic alloy ribbons, and then one of the cut ends is placed on the smooth attracting surface of the electromagnet. The amorphous magnetic alloy ribbon group is bent along the outer peripheral surface of the cored bar. However, in this case, a large number of laminated amorphous magnetic alloy ribbons are forced to have a large relative movement (sliding), and in some cases there is a risk of cracking.

  The reactor device using the amorphous material of the present invention has a structure in which a wound iron core unit in which a plurality of laminated amorphous materials obtained by laminating a plurality of amorphous strips cut to a predetermined length are butted together at a plurality of unit butt joints. It is characterized by being divided or more.

  Furthermore, the reactor apparatus using the amorphous material of the present invention is characterized in that butt joining is performed at the corners of the iron core unit.

  Further, in the reactor device using the amorphous material of the present invention, the relationship between the laminated thickness (t) composed of the plurality of amorphous ribbon materials and the receding dimension (s) when the laminated amorphous material is laminated, It is a wound core unit that is stacked so that t = s.

  Furthermore, the reactor device using the amorphous material of the present invention is characterized in that a plurality of wound core units are butt-joined via a gap member in the butt-joining portion.

  Furthermore, the reactor device using the amorphous material of the present invention is characterized in that each of the wound core units is held by a shape-retaining member.

  Furthermore, the reactor device using the amorphous material of the present invention is characterized in that the central portion of the butt joint portion of the wound core unit has a convex shape and the butt area is small.

  A method for manufacturing a reactor apparatus using an amorphous material according to the present invention includes a step of cutting a thin amorphous ribbon material into a predetermined length and laminating a predetermined number of layers, and stacking the laminated amorphous material in a plurality of stages to form a wound core unit. It is characterized in that a plurality of units are prepared and molded and then annealed and assembled as a unit.

  Furthermore, the manufacturing method of the reactor apparatus using the amorphous material according to the present invention is to cut the amorphous ribbon material into a predetermined length and laminate a predetermined number of layers, and stack the laminated amorphous material in a plurality of stages to constitute a wound core unit. The center portion of each of the laminated amorphous materials is stacked together.

  With the reactor device having a novel configuration of the present invention, a large-capacity reactor using an amorphous material can be manufactured. More specifically, according to the manufacturing method of the present invention, since the wound core unit is not first assembled and then cut, the core having a large cross section and a large capacity reactor can be manufactured.

  Further, in the reactor device of the present invention, it is not necessary to harden the wound core unit with resin for cutting, and no stress due to cutting is applied, so that deterioration of iron loss can be suppressed. Moreover, the freedom degree at the time of iron core shaping | molding can be raised, and the reactor apparatus using a large sized amorphous material and a highly efficient reactor apparatus can be manufactured.

The structure figure of the reactor apparatus of this invention is shown. The schematic image figure of the whole process of the manufacturing method of the reactor apparatus of this invention is shown. The image figure of the bending process of the manufacturing method of the reactor apparatus of this invention is shown. The image figure of the lamination process of the manufacturing method of the reactor apparatus of this invention is shown. Fig. 4 shows a wound core unit formed after a cutting-lamination-stacking-bending-shape-retaining step. The shape-retaining part details of the formed wound core unit as seen from the B direction in FIG. 3A are shown. One Example of the wound core unit butt-joined is shown. The other Example of the wound iron core unit butt-joined is shown. Yet another embodiment of a wound core unit butt-joined is shown. The structure which took the countermeasure against the fragmentation at the time of fabrication of the wound core unit after annealing is shown. The fixing method of the reactor apparatus of this invention is shown. The schematic structure of the reactor apparatus of this invention is shown. The schematic structure of the reactor apparatus of another Example which gave the countermeasure against fringing is shown. The detailed drawing of the wound core structure of the reactor apparatus of another Example is shown. The manufacturing process of the wound core unit of the reactor apparatus of another Example is shown. The shape retention state of the wound core unit of the reactor apparatus of another Example is shown. The image figure of the cutting-lamination-stacking process of the manufacturing method of the reactor apparatus of this invention is shown. The image figure of the butt connection part of the reactor apparatus of this invention is shown.

  In the reactor device of the present invention, in order to solve the above problem, as shown in FIG. 1, a plurality of wound core units divided in advance from the time of winding core production are manufactured, and these are assembled and manufactured. is there. At that time, the magnetic flux density can be increased by increasing the cross-sectional area of the butt joint by bringing the connecting part to the corner part (R part) of the wound core unit without hardening the wound core unit with resin or the like. It is possible to suppress the fringing phenomenon that occurs at the joint.

  FIG. 1 shows a schematic configuration diagram of a reactor device 10 of the present invention. In the present invention, as shown in FIG. 1, a plurality of amorphous coil thin plate materials are previously cut and stacked, and the wound core units 2 a and 2 b formed after stacking a plurality of stacked amorphous materials are stacked. Separately, by combining coil units 1a and 1b made in advance, the reactor units 10a and 10b are divided into a plurality of pieces in advance, and then assembled in the direction of the arrow. At that time, the wound iron core units 2a and 2b are held in shape by tightening with the fastening screw means 3 and 3 without being held in shape with resin or the like. The butt joint portion 4 of each wound core unit 2a, 2b is a corner portion (R portion) 5 of the iron core, and the butt portion 4 is a cut surface 4a, 4b portion. An embodiment of a method for manufacturing the reactor device 10 of the present invention will be described below.

  The example of the manufacturing method of the reactor unit 10a is demonstrated sequentially using figures. FIG. 2A shows a cutting element of the wound core unit 2 prepared by unwinding the amorphous coil material 20 wound with an amorphous thin plate material and stacking the amorphous material cut into a predetermined length by the stopper 21 and the cutting means 22. An image diagram is shown. At the time of cutting shown in FIG. 2A, the cutting length and overlapping position of the amorphous material are calculated in advance so as to have a shape as shown in the drawing. After cutting, as a method of forming the wound core unit 2, the wound core unit 2 on the support member 23 is bent along a bending die 25 by a press machine (not shown) as shown in FIG. 2B. Reference numeral 24 can be used as a fixed core after bending. As a fixing method of the wound core unit 2, the fixed core metal 32 is fastened and fixed with a plurality of screws 33 as shown in FIG. 3A. FIG. 3B is a side view of the iron core unit 2 shown in FIG. 3A, and the wound iron core unit 2 is sandwiched between the fixed core metal 32 and fastened with a plurality of screws 33.

  The actual thickness of the amorphous coil thin plate material 20 is 0.0235 mm, 5 to 20 sheets are cut to the same length, and a plurality of layers are laminated, and the laminated bodies 20a, 20b, 20c, 20d, .. Are stacked to form the wound core unit 2. Therefore, as shown in FIG. 2C, the end surface of the wound core unit 2 is formed in steps.

  Furthermore, the cutting-lamination-stacking process of the amorphous coil thin plate material 20 is shown in FIG. The amorphous coil material 20 wound with the amorphous thin plate material is rewound, abutted against the stopper 21, and cut into a predetermined length by the cutting means 22. At this time, the length of the amorphous coil thin plate material 20 to be cut is determined by the distance (l) between the stopper 21 and the cutting means 22. The distance (l) between the stopper 21 and the cutting means 22 is determined by the stopper 21 and the fixed cutting blade 28 that are screw-engaged with the drive screw 27. The distance (l) can be changed by rotating the drive screw 27 by the motor 26.

  Here, since the actual plate thickness of the amorphous coil sheet material 20 is 0.0235 mm, when 5 to 20 sheets are cut into the same length and stacked in a plurality of stages, the laminated body 20a of the amorphous coil sheet material 20a. , 20b, 20c, 20d... Is 0.1175 to 0.4700 mm. The lengths of the stacked bodies 20a, 20b, 20c, 20d,... Differ from each stacked stage by a length s. If the length of the laminate 20a of the longest amorphous coil thin plate material inside the reactor device window is La, the lengths Lb, Lc, Ld of the next-stage laminates 20b, 20c, 20d. Lb = La−2s, Lc = Lb−2s, Ld = Lc−2s... (FIG. 2C).

  Next, although not shown, the wound core units 2a and 2b are annealed in a magnetic field in order to remove stress from the wound core units 2a and 2b, shape the iron core, and impart magnetic direction to the amorphous material. At the time of the main annealing, annealing is performed in the shape of the completed wound core as shown in FIGS. 4A, 4B and 4C so that the iron core forms a closed magnetic circuit. Desirably, the butt connection portion 4 of the wound core unit 2 is arranged at the corner portion (R portion) 5 of the reactor device, but the arrangement position can be selected. Although not shown, two or more wound core units 2 can be used in an appropriate number.

  The wound core unit 2 cut, laminated and stacked from the process shown in FIG. 2A is bent by the process shown in FIG. 2B. The wound core unit 2 cut, laminated, and stacked in the state shown in FIG. 2C is bent with the short-length laminated body inside, so that the difference dimension (s ′) of the length of each step is The value is smaller than S (s> s ′). This is because the bending radius of the laminated outer amorphous thin plate material becomes larger.

  In this case, the lamination thickness (t) of the laminates 20a, 20b, 20c, 20d ... of the amorphous coil thin plate material and the lengths of the laminates 20a, 20b, 20c, 20d ... of each step after the bending process. By making the difference dimension (s ′) substantially the same, the butt connection portion 4 of the reactor device can be configured without a gap as shown in FIG. At that time, the cutting length control of the amorphous coil thin plate material at each stage can be achieved by controlling the rotation of the motor 26 by a control device (not shown). At that time, the position of the intermediate point 29 between the stopper 21 and the fixed cutting blade 28 is fixed at a fixed position. Thereby, the laminated body 20a, 20b, 20c, 20d,... Of the amorphous coil thin plate material at each stage is laminated and stacked with the central portion of the bisect length positioned at the intermediate point 29. Thereby, the steps of both end portions are formed in the same manner by bending.

  As shown in FIG. 5, the wound core unit 2 after annealing is provided with a fixing metal fitting 51 inside the window of the wound core unit 2, wrapped around the wound core unit 2 with insulating paper (not indicated), and wound with a filament tape 52. In addition to insulation, this insulating paper also serves as a measure to prevent debris scattering of the amorphous material, so be careful not to tear the insulating paper. Further, in order to form a predetermined gap when each winding core unit is abutted in the abutting portion in FIG. 5, not only the insulating paper but also a press board or the like has a strength and a thin material via a gap member 53. Fix it.

  FIG. 6 shows a method for assembling the contents of the reactor unit 10. The legs of the formed wound core units 2a and 2b are put into the coil units 1a and 1b, and the parts of the reactor units 10a and 10b are assembled as shown in FIG. As shown in FIG. 6, the reactor units 10a and 10b are fixed by sandwiching the wound core units 2a and 2b from above and below by pressing the contents fixing brackets 61 and 62 from above and below. The iron core units 2a, 2b and the coil units 1a, 1b are fixed in the contents fixing brackets 61, 62.

  As shown in FIG. 7, the magnetic characteristics of the reactor device 10 are adjusted by sandwiching a gap member (reference numeral 53 in FIG. 5) such as a press board (not indicated) in the butt joint 4 and finely adjusting the gap. Or, it is adjusted by adjusting the tightening strength of the contents fixing brackets 71 and 71 (the specific adjustment method is omitted).

  A feature of the reactor device 10 of the present invention is that the magnetic characteristics can be adjusted in the assembled state (FIG. 7) of the contents. Moreover, even if the capacity | capacitance becomes large, the reactor apparatus 10 of this invention can be manufactured with the same manufacturing method by manufacturing a wound core unit previously. Moreover, since it is not necessary to harden the wound core units 2a and 2b with resin, it is possible to suppress the deterioration of the iron loss. Furthermore, since the wound core units 2a and 2b are abutted at the corners 5, the cross-sectional area of the joint between the wound core units where fringing occurs increases, so that the magnetic flux density of the core joint can be suppressed. It is possible to suppress deterioration of reactor characteristics and increase in noise due to fringing.

  Furthermore, as another example of the present invention, Example 2 is shown below for an iron core shape specialized for fringing countermeasures. In the second embodiment, as shown in FIG. 8, the butt center portion of the wound core units 9a and 9b is formed in a convex state to suppress the deterioration of fringing. FIG. 9 shows a joining image of the butted portion A of the wound core unit 9a, 9b in that case. Fringeing is a phenomenon in which magnetic flux leaking from the gap portion at the butt joint of the wound core units 9a and 9b collects on the outer peripheral side of the core. Therefore, by making the butt joint of the wound core units 9a and 9b convex at the center as shown in FIG. 9A, the magnetic flux is concentrated at the center of the core cross section, and the leakage magnetic flux is again in the core. The purpose of the structure of the second embodiment is to increase the apparent sectional area.

The manufacturing method of the reactor device of the second embodiment is almost the same as that of the first embodiment. The wound core material is drawn out for a predetermined length, cut and laminated as shown in FIG. 10, and then the wound core unit 9a is fixed. A wound core that is placed on the table 12 and formed around the core core 13 on the fixed core 14 of the core by a press machine (not shown) and is the contents of the reactor device as shown in FIG. The units 9a and 9b and the coil units 8a and 8b are assembled.
FIG. 11 shows a shape retention state of the wound core unit of the reactor device according to the second embodiment.

DESCRIPTION OF SYMBOLS 10 ... Reactor apparatus 1a, 1b ... Coil unit 2a, 2b ... Amorphous winding iron core unit 3 ... Fastening screw 4 ... Butt joint 5 ... Corner | angular part 52 ... Filament tape 23, 12 ... Material fixing bases 24, 32 ... Iron core fixing cores 25, 14 ... Bending die 51 ... Iron core fixing brackets 5d, 7e, 9b ... Iron core connecting portions 61, 62, 71 ... Contents fixing bracket

Claims (8)

  Amorphous material characterized in that it is divided into two or more parts by butting together a wound core unit in which a plurality of laminated amorphous materials obtained by laminating a plurality of amorphous strips cut at a predetermined length at a plurality of units butting joints Reactor device using.   The reactor apparatus of Claim 1 WHEREIN: The reactor apparatus using the amorphous material characterized by butt-joining at the corner | angular part of the said iron core unit.   3. The reactor device according to claim 2, wherein a relationship between a laminated thickness (t) made of the plurality of amorphous ribbon materials and a receding dimension (s) when the laminated amorphous material is laminated is t = s. Reactor device using amorphous material, characterized by being stacked core units.   The reactor apparatus of Claim 1 WHEREIN: In the said butt | joining junction part, the several wound core unit is butt-joined via the clearance gap member, The reactor apparatus using the amorphous material characterized by the above-mentioned.   5. The reactor device according to claim 1, wherein each of the wound core units is held by a shape-retaining member.   The reactor device according to claim 1, wherein the center portion of the butt joint portion of the wound core unit is convex, and the butt area is small.   Amorphous ribbon material is cut into a predetermined length and stacked in a predetermined number, and the laminated amorphous material is stacked in multiple stages to form a wound core unit. After preparing and forming a plurality of the wound core units, they are annealed and integrated. A method of manufacturing a reactor device using an amorphous material characterized in that it is assembled as   8. The method of manufacturing a reactor device according to claim 7, wherein when the amorphous ribbon material is cut into a predetermined length and a predetermined number of layers are stacked, and a plurality of the stacked amorphous materials are stacked to form a wound core unit, each of the stacked layers A method of manufacturing a reactor device using an amorphous material, characterized by stacking together a central portion of the amorphous material.

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