JP2018078207A - Stacked iron core, manufacturing method thereof, and power transformer using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stacked iron core capable of improving a laminating workability and reducing a loss of a joint part.SOLUTION: A stacked iron core 100 is constructed by laminating a plurality of unit stacked iron cores. The unit stacked iron core is structured by: an upper yoke laminate body 103a; a lower yoke laminate body 103b; and a leg part laminate body 104 that connects the upper yoke laminate body and the lower yoke laminate body. The upper yoke laminate body and the lower yoke laminate body are formed by laminating two or more kinds of iron core materials 105 each having a different width so that one end is aligned and the other end becomes a step state. The leg part laminate body is formed by laminating the two kinds or more iron core materials having the different width so that both ends become the step state. The unit stacked iron core is formed by laminating the step like end parts of the upper yoke laminate body and the lower yoke laminate body, and the step like end parts of the leg part laminate body.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a core product made of amorphous alloy ribbon, a manufacturing method thereof, and a transformer using the same.

  As one of the structures of the iron core of a transformer, there is a stacked iron core that forms an iron core by stacking plate-like magnetic materials such as silicon steel plates to a predetermined thickness.

  As an example of the iron core, Patent Document 1 states that “at least a pair of left and right upper yoke parts between a horizontally long rectangular upper yoke part and a horizontally long rectangular rectangular lower yoke part having the same lateral length as the upper yoke part. In a strip-shaped core structure with the same vertical length and a rectangular leg, the lower edge of the upper yoke and the upper edge of the leg abut each other without a gap. The lower end edge and the upper end edge of the lower yoke part abut each other without any gaps, and the upper yoke part and the lower yoke part are located between the upper and lower yoke parts adjacent to each other in the stacking direction. The vertical length is different, and the upper yoke portion and the lower yoke portion of each layer have the same vertical length, and the upper yoke portion and the lower yoke portion have three or more types of vertical lengths. A stacked core structure characterized in that different yoke members are selected and combined. ”(Claim 1)

  Further, as an iron core using an amorphous alloy ribbon, Patent Document 2 states that “at least two core core legs laminated with amorphous alloy ribbons cut into a predetermined shape, and a lower yoke and an upper yoke are joined. In the transformer core that forms a closed magnetic path, the core main leg, the lower yoke, and the upper yoke are each unit laminated with a thermosetting resin provided with positioning holes at predetermined positions. A plurality of magnetic bodies are combined and formed, and the positioning holes are composed of laminated core elements in which penetrating supports are arranged, and are integrated in accordance with the outer surface shapes of the joined core main legs and the lower yoke. Comb-shaped core support members are disposed on both surfaces of the core main leg and the lower yoke, plate-shaped core support members are disposed on both surfaces of the upper yoke, and the comb-shaped core support members and the plate-shaped core support The connection between members depends on the connecting member The comb-shaped core support members that are coupled and disposed on both surfaces of the lower yoke, and the plate-shaped core support members that are disposed on both surfaces of the upper yoke are respectively connected by shape holding members. "A transformer core for transformers" (Claim 1).

Utility Model Registration No. 3189478 JP 2013-118254 A

  The stacked iron cores described in Patent Document 1 are obtained by sequentially stacking iron cores having different vertical lengths (widths) in adjacent upper yoke portions and lower yoke portions in the stacking thickness direction. There exists a subject that a process takes time.

  In addition, the laminated iron core disclosed in Patent Document 2 is formed by laminating amorphous alloy ribbons and integrating them with a thermosetting resin to form a unit laminated magnetic body. Although it is described that iron and an upper yoke are constituted, unit laminated magnetic bodies are sequentially stacked to form a laminated core element, and there is still a problem in workability.

  In particular, since the amorphous core is composed of an amorphous alloy ribbon that is a very thin ribbon of approximately 25 μm, an enormous number of core materials are required if the mass is equivalent to that of a core made of silicon steel. It becomes. Therefore, there is a problem that it takes time for the lamination process and the slit process of the iron core material.

  An object of the present invention is to provide a stacked iron core capable of improving the laminating workability and reducing the loss of the joint.

  In order to solve the above problems, one of the cores according to the present invention includes a yoke laminate and a leg laminate in which two or more kinds of blocks having different material widths are laminated in order from a block having a longer or shorter material width. This is achieved by using the body as a basic part and laminating it to form a product core.

  An example of the product core of the present invention is a product core formed by stacking a plurality of unit product cores, and the unit product core includes an upper yoke part laminate, a lower yoke part laminate, and the upper yoke part laminate. The upper yoke part laminate and the lower yoke part laminate are composed of two or more different core materials having different widths at one end. And the other end of the leg laminate is a laminate of core materials of two or more different widths so that both ends are stepped. The unit cores are stacked such that the stepped ends of the upper yoke layer stack and the lower yoke layer stack are combined with the stepped ends of the leg layer stack.

  An example of a method for producing a core product according to the present invention is a method for producing a core product in which a plurality of unit product cores are stacked, so that two or more types of core material having different widths are aligned at one end, and Laminate the other end in a staircase to form an upper yoke layer stack and a lower yoke layer stack, and stack two or more different widths of core material so that both ends are stepped. And the stepped end portions of the upper yoke portion stacked body and the lower yoke portion stacked body are overlapped with the stepped end portions of the leg stacked portion. And a step.

  According to the present invention, the conventional laminating operation for each block in the laminating process is not necessary, and the stacked iron core can be configured by simply stacking in units of several blocks. Be improved. Moreover, by preparing a laminated body constituted by laminating a plurality of blocks as a basic part before the lamination work, the number of stacking operations in the lamination process can be reduced, and workability can be improved.

  As for the iron core characteristics, the joint between the leg and the yoke can be shifted for each block, and the step lap joint with one block as a stack unit can reduce the loss due to the transition of the magnetic flux at the joint. Is possible.

It is a figure which shows the stacked iron core of Example 1 of this invention, (a) is a front view, (b) is a side view. It is a perspective view which shows the yoke part laminated body and leg part laminated body of the 1st step | paragraph of the laminated body of the laminated iron core of this invention. It is a figure which shows the manufacturing process of the product core of Example 1 of this invention. It is a side view which shows the stacked iron core of Example 2 of this invention. It is a side view which shows the insertion operation | work of the upper yoke part in the stacked iron core after coil insertion. It is a figure which shows the stacked iron core of Example 3 of this invention, (a) is a front view, (b) is a side view. It is a schematic front view which shows an example of the transformer of Example 4 of this invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that in the drawings for describing the embodiments, the same components are denoted by the same names and reference numerals as much as possible, and the repeated description thereof will be omitted.

  FIG. 1 shows a stacked iron core according to Example 1 of the present invention. FIG. 1 (a) shows a front view and FIG. 1 (b) shows a side view. The stacked iron core 100 includes an upper yoke portion 101a, a lower yoke portion 101b, and leg portions 102 that connect them. As shown in FIG. 1B, the upper yoke portion 101a and the lower yoke portion 101b are configured by stacking a plurality of yoke portion laminates 103. Similarly, the leg portion 102 is configured by laminating a plurality of leg laminates 104. In the figure, reference numeral 107 denotes the thickness of one laminated body. The yoke part laminated body 103b constituting the lower yoke part 101b has a plurality of magnetic material blocks (iron core materials) 105 having a constant horizontal width X and different distances (vertical widths) from the lower end to the upper end from Y1 to Y3. It is configured by stacking with the bottom ends aligned. Similarly, the yoke laminated body 103a constituting the upper yoke portion 101a has a plurality of magnetic material blocks (iron core materials) 105 having a uniform lateral width and different distances (vertical widths) from the upper end to the lower end. And are laminated.

  The leg laminate 104 constituting the leg 102 is laminated such that a plurality of blocks 105 of magnetic materials having a constant lateral width and different distances (vertical widths) from the lower end to the upper end are shifted slightly from each other. Is configured. The distance (vertical width) from the lower end to the upper end of the leg laminate 104 is the lower end of the yoke laminate 103a constituting the upper yoke 101a and the upper end of the yoke laminate 103b constituting the lower yoke 101b. The width according to the distance. In the figure, reference numeral 106 indicates the thickness of one block of the magnetic material.

  The magnetic material block 105 may be one block made of several dozen amorphous ribbon alloys, or one block of silicon steel plate, or one block made of a plurality of layers. Things can be used.

  FIG. 2 shows the yoke laminates 103a and 103b and the leg laminate 104 composed of a plurality of types of blocks having different widths. FIGS. 1 and 2 show examples of the yoke laminates 103a and 103b and the leg laminate 104 configured by blocks of three kinds of material widths. The material width is, for example, Y1 = 142 mm, Y2 = 170 mm, Y3 = 213 mm, which are the widths of the amorphous material used in the iron cores for power transformers currently sold in the market. There is no limitation on the combination and type of dimensions, such as using a material with an arbitrary width that has been slit.

  As shown by the arrows in FIG. 2, a yoke laminate 103a with the upper end face aligned and a yoke laminate 103b with the lower end face aligned are arranged, and the leg stacks are connected so as to connect both yoke laminates. The body 104 is stacked. The lamination of the leg laminate is performed such that the stepped portion of the yoke laminate and the stepped portion of the leg laminate are combined so that the gap between the joints is very small.

In FIG. 3, the manufacturing process of the product core of a present Example is shown.
3A and 3B show a manufacturing process of the yoke laminate 103, in which a plurality of types of blocks (iron core materials) 105 having different widths are laminated with their ends aligned and integrated with an adhesive or the like. . Reference numeral 108 denotes an adhesion location. The adhesion location may be the side surface of the laminate shown in the figure, or the blocks may be adhered.
FIGS. 3C and 3D show the manufacturing process of the leg laminate 104, in which a plurality of types of blocks (iron core materials) 105 having different widths are laminated with their side surfaces aligned and integrated with an adhesive or the like. .
The yoke laminate 103 and the leg laminate 104 may be integrated by bonding with a coating agent such as resin or rubber. By integrating, strength is obtained and handling becomes easy.

  3E to 3G show a stacking process of the yoke stack 103 and the leg stack 104. FIG. As shown in FIG. 2, the yoke laminate having the upper end face aligned and the yoke laminate having the lower end face aligned are arranged, and the leg laminate 104 is connected so that both yoke laminates 103 are connected. Stack up. By laminating the yoke laminate 103 and the leg laminate 104, a unit product core 110 shown in FIG. 3F is obtained. Further, as shown in FIG. 3G, the product core is obtained by sequentially stacking the yoke laminate 103 and the leg laminate 104 on the unit product core 110.

  According to the present embodiment, the number of parts used in the laminating process can be obtained by using the yoke laminate 103 and the leg laminate 104 in which blocks having different widths are laminated and integrated as basic components constituting the core. Can be reduced, and the laminating workability, which is a problem of the iron core, can be improved. Then, after installing the yoke laminate 103 with the outer peripheral end surfaces aligned, by laminating the leg laminate 104, the conventional operation of laminating each block becomes unnecessary, and the blocks are simply stacked in units of several blocks. Therefore, the workability in the laminating process can be improved.

  In addition, the yoke stack and leg stack can be bonded and fixed with a coating agent, etc., with the outer peripheral end faces aligned, thereby suppressing misalignment in the stacking process and further shortening the work time. it can.

  As for the iron core characteristics, the joint between the leg portion and the yoke portion can be shifted for each block, and the step lap joint with one block as a unit of lamination results in a reduction in loss due to the magnetic flux at the joint. be able to.

  In FIG. 4, the side view of the stacked iron core of Example 2 of this invention is shown. In the iron core structure shown in the first embodiment, the second embodiment configures the yoke stack and the leg stack every even number of stages when the yoke stack 103 and the leg stack 104 are stacked in a plurality of stages. The block stacking order is reversed and the stacking is repeated.

  As shown in the figure, the odd-numbered yoke layer stack gradually decreases in block order in the order in which the blocks 105 are stacked, while the even-numbered yoke section stack gradually increases in block width in the order in which the blocks are stacked. Becomes wider. Correspondingly, in the leg stack 104, the odd-numbered yoke section stack gradually becomes wider in the order in which the blocks 105 are stacked, but the even-numbered yoke section stack in the order in which the blocks are stacked. Gradually the width of the block becomes narrower. Note that the yoke stack 103 and the leg stack 104 are stacked in the odd-numbered stage in which two yoke stacks are arranged and the leg stack is stacked thereon. The even-numbered stack is the leg stack. The body 104 may be disposed, and the yoke laminate 103 may be stacked thereon.

FIG. 5 shows a case where the iron core material of the upper yoke portion is removed, the iron core is self-supporting, the coil is inserted into the leg portion, and then the work of inserting the iron core material of the upper yoke portion is performed again. In the iron core structure shown in FIG. 4 of the second embodiment, the even-numbered yoke portion laminated body 103d and the odd-numbered yoke portion laminated body 103e are removed together, so that the upper portion of the iron core structure shown in FIG. The space of the insertion portion in the stacking direction of the joint surface between the yoke portion and the leg portion is widened.
Also, as shown in FIG. 5, by bonding and fixing the two upper yoke laminates 103d and 103e with a coating agent or the like, the material becomes rigid and easy to insert, and the number of insertion operations is reduced. Workability is improved.

  According to the present embodiment, the odd-numbered yoke portion laminate and the even-numbered yoke portion laminate are configured such that the change in the width of each block in the stacking direction is reversed. It becomes easy to re-install after inserting.

  FIG. 6 shows a stacked iron core according to Example 3 of the present invention. FIG. 6 (a) is a front view and FIG. 6 (b) is a side view. Example 3 is the iron core structure shown in Example 1, in which silicon steel plates are arranged at the lowermost and uppermost stages of the core.

  6B, reference numeral 112b indicates a silicon steel plate provided at the lowest stage of the stacked iron core, and in FIG. 6A, reference numeral 112a indicates a silicon steel sheet provided at the uppermost stage of the stacked iron core.

  By providing the silicon steel plate 112 at the lowermost stage and the uppermost stage of the stacked core, the strength of the stacked core can be increased and protected. In particular, in an iron core using a magnetic material block in which amorphous ribbons are stacked, the amorphous ribbon can be prevented from being broken.

  In FIG. 7, the schematic front view of an example of the transformer of Example 4 of this invention is shown. A present Example is a transformer provided with the product core 100 and the coil 200 of Example 1. FIG.

  As shown in the figure, a coil 200 is inserted into each leg portion 102 of the product core 100 to constitute a transformer.

100 Iron core 101 Yoke part
101a Upper yoke part 101b Lower yoke part 102 Leg part
103 Yoke part laminate
103d Even-numbered yoke portion laminate 103e Odd-numbered yoke portion laminate 104 Leg-layered body
105 blocks (iron core material)
106 1 block thickness
107 1 Laminate thickness
108 Bonding points
109 Junction 110 Unit Product Core 112 Silicon Steel Plate 200 Coil

Claims (14)

It is a core made by stacking multiple unit cores,
The unit product iron core is composed of an upper yoke part laminate, a lower yoke part laminate, and a leg laminate that connects the upper yoke part laminate and the lower yoke part laminate,
The upper yoke part laminate and the lower yoke part laminate are obtained by laminating two or more types of core materials having different widths so that one end is aligned and the other end is stepped.
The leg laminate is a laminate of two or more different widths of core material so that both ends are stepped,
The unit cores are stacked so that the stepped end portions of the upper yoke layer stack and the lower yoke layer stack are combined with the stepped ends of the leg layer stack. A featured iron core. In the iron core according to claim 1,
The iron core material is a block in which a plurality of amorphous alloy ribbons are stacked. In the iron core according to claim 1,
The iron core material is a single iron steel plate or a block obtained by laminating a plurality of silicon steel plates. In the iron core according to claim 1,
Each of the upper yoke part laminated body, the lower yoke part laminated body, and the leg laminated body is integrated. In the iron core according to claim 1,
Each of the upper yoke part laminated body, the lower yoke part laminated body, and the leg laminated body is bonded and fixed with a coating agent. In the iron core according to claim 1,
In the upper yoke layer stack, the lower yoke layer stack, and the leg layer stack, the change in the width of the core material having the different width is reversed between the odd-numbered and even-numbered layers of the unit cores. Stacked iron core, characterized by being laminated like this. In the iron core according to claim 6,
At least a part of the odd-numbered upper yoke laminate and the even-numbered upper yoke laminate are integrated. In the iron core according to claim 1,
A laminated iron core characterized in that silicon steel plates are attached to the lowermost and uppermost stages of the laminated iron core. A first yoke portion disposed on the upper side of the iron core, a second yoke portion disposed on the lower side of the iron core, a first connection portion connected to the first yoke portion, and the second A steel core including a leg portion having a second connection portion connected to the yoke portion of
The iron core is stacked with iron core members from the front side surface toward the back side surface,
The portion of the first yoke portion connected to the first connecting portion has a distance from the upper side to the lower side of the first yoke portion that increases in a stepped manner from the near side surface to the far side surface. Are lined up like
The portion of the second yoke portion that is connected to the second connecting portion has a stepwise longer distance from the front surface to the back surface from the lower portion to the upper portion of the second yoke portion. Are lined up like
The legs are arranged such that the distance between the upper end of the first connecting portion and the lower end of the second connecting portion is shortened stepwise from the near side to the far side. Seki iron core to do. A method of manufacturing a core product in which a plurality of unit product cores are stacked,
Laminating two or more kinds of core materials having different widths so that one end is aligned and the other end is stepped to form an upper yoke part laminate and a lower yoke part laminate;
A step of laminating two or more kinds of core materials having different widths so that both ends are stepped, and forming a leg laminate,
Superposing the stepped ends of the upper and lower yoke stacks so as to be combined with the stepped ends of the leg stacks;
A method for manufacturing a steel core comprising: The method of manufacturing a core product according to claim 10, further comprising:
A method of manufacturing a laminated iron core, wherein the step of overlapping the stepped end portions of the upper yoke portion laminate and the lower yoke portion laminate and the stepped end portions of the leg portion laminate is repeated. In the manufacturing method of the iron core according to claim 10,
The core material is a block in which a plurality of amorphous alloy ribbons are laminated. In the manufacturing method of the iron core according to claim 10,
The iron core material is a silicon steel plate or a block in which a plurality of silicon steel plates are laminated.   A transformer comprising the product core according to any one of claims 1 to 9 and a coil.

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