JP2578160B2 - Transformer manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (a) Industrial application field The present invention relates to the production of a transformer having a large capacity, in particular, a primary side coil and a secondary side coil wound around a core leg of a seamless wound core. Using a specially shaped copper plate type coil, these coils are laminated on the iron core legs while interposing an insulator, and the transformer is assembled, which may cause deterioration in magnetic characteristics during operation and so-called aging such as noise generation. It is an object of the present invention to establish a method of manufacturing a transformer which has no load current, has very little current, and can be easily disassembled and repaired.

(B) Conventional technology Conventionally, when a transformer using a wound iron core and having no seam is used for the wound iron core, the operation of winding a coil around the iron core leg is complicated, and especially for a large capacity transformer. A seamless core is rarely used. Therefore, looking at the current manufacturing method of transformers using wound iron cores, the entire wound iron core is fixed with an adhesive and then cut at two locations. Joined and suitable for making small and medium capacity transformers. As described above, the split-shaped wound core (hereinafter, referred to as a cut core) obtained by cutting two portions of the seamless wound core is used by mechanically joining the cut surfaces. High accuracy is required as a processing method,
A lot of trouble is required for the processing method.

That is, if the accuracy of the finished surface of the joint surface at the two cut portions is insufficient, a gap remains at the joint surface portion, and the magnetic resistance at this portion increases.

Also, when a seamless wound core is cut, the shape of the cut surface is deformed, and these two surfaces are mechanically tightened, for example.
Even if they are abutted, it is difficult to completely overlap these two surfaces, which also causes an increase in magnetic resistance. Further, when the iron core is cut by a mechanical means, the magnetic properties of the iron core deteriorate due to the residual stress received during the cutting. For this reason, transformers manufactured using the KATO CORE generate beats during operation, become a noise source, increase the no-load current, and have the problem that the characteristics of the transformer are reduced.
In particular, many large-capacity transformers use an iron core, and few use a cut core.

(C) Problems to be solved by the invention The conventional method of manufacturing a transformer using a cut core is, for example, to manufacture a copper plate-type primary coil that can be fitted to an iron core leg, After being fitted into the cut core, the cut surfaces of the wound core are butt-bonded mechanically to be joined. When a transformer is manufactured using such a method, as described in section 3. (b), if the butt joint surface is insufficiently processed, a gap will remain at the joint, and the magnetoresistance of this joint will remain. This causes problems such as generating a beat during operation, becoming a noise generation source, and increasing the no-load current of the transformer. In order to eliminate this cause, it is necessary to finish the four cut surfaces obtained when the wound core is cut at two places, that is, to make the joint surface a mirror surface, in order to reduce the gap at the joint. is there. By the way, in the transformer where the current capacity actually flows from tens of thousands of amperes to more than 200,000 amperes, the size of the cut surface of the wound core is several hundred square cm or more, and the core leg of such a large capacity transformer is wide. It is very difficult to finish the joint surface with high precision so as to be a mirror surface, and when the wound core is cut, geometric deformation occurs on the outer periphery of the core,
The perfect superposition of two large-area joining surfaces is also very difficult and requires a great deal of effort for this adjustment. In addition, the reduction of the magnetic properties of the magnetic material due to the residual stress applied to the core legs of the seamless wound core and the iron core legs during mechanical cutting cannot be ignored, and these drawbacks are in particular the application of cut cores to large capacity wound core transformers. It is one of the factors that hinders.

The present invention provides a transformer for winding a primary side coil and a secondary side coil around a core leg of a seamless wound core easily and inexpensively without using a cut core having many problems as described above. It is intended to provide a method for manufacturing a vessel.

(D) Means for Solving the Problems As an example of the embodiment of the present invention, a case where a normal copper plate type one-turn coil is used for the primary side coil and a copper plate type U-shaped coil is used for the secondary side coil This will be described with reference to the drawings.

FIGS. 1 (1) and 1 (2) show an outline of an assembling procedure. FIG. 1 (1) shows a primary side copper plate manufactured using a thick copper plate shown in FIG. 2 (1). Type 1 turn coil 3 ,
For example, two seamless wound iron cores 1 and 2 are fastened to each other with a band (not shown), and iron core legs I and
The opening 5 covered by the lead portions 4, 4 'of the primary-side copper plate-type one-turn coil 3 is formed in the cross section of the iron core having the width a and the thickness b shown in FIG. It is opened to the extent that the core cross section width a constituted by the iron core legs I and II can be pushed through, and it is fitted into the iron core legs while pushing.

In this way, the required number of primary-side coils determined by design is insulated to the iron core legs by about 1/2 of the height h of the window of the seamless wound iron core designed from the transformer capacity and other factors. This shows a state when the layers are stacked while the object P is interposed.

Next, a method of inserting the secondary coil will be described. That is, FIG. 1 (2) shows a primary coil and a primary coil in which the required number of thin copper plate type one-turn coils 3 shown in FIG. 2 or the primary coil 3 shown in FIG. 2 (2) while the insulator P is interposed between the primary coils stacked on each other.
More usually, the opening 8 of the U-shaped portion 6 of the thick U-shaped copper plate type secondary coil 9 is inserted into the portion of the iron core cross section a constituted by the iron core legs I and II with the insulator P interposed therebetween. This shows a state in which the layers are stacked. Two L-shaped coil pieces 7, 7 'provided at both ends of the opening 8 of the U-shaped portion 6 of the secondary coil.
Also serves as a coil lead wire.

Thus, the U-shaped portion 6 of the primary copper plate type one-turn coil 3 and the secondary side copper plate U-shaped coil is connected to the iron core widths I and II of the seamless wound iron core. Lamination can be easily performed while an insulator is interposed in the portion a. In this way, the primary-side copper-plate-type one-turn coil 3 and the secondary-side copper-plate-type coil 9 are inserted and laminated in the portion of the core width a constituted by the core legs I and II of the seamless wound core. In order to actually operate as a transformer, the one-turn coil in the primary copper plate type one-turn coil 3 may be connected so that the respective one-turn coils are connected in series at the coil extraction portions 4, 4 '. The secondary copper plate-shaped U-shaped coil 9 may be connected in parallel by attaching two L-shaped coil pieces 7, 7 'to the U-shaped portion 6 of the secondary copper plate-shaped coil 9 .

From the above, it is possible to easily, inexpensively, and manufacture a transformer having excellent characteristics using a seamless wound iron core. FIG. 3 (1) is a front view schematically showing two seamless wound iron cores, and FIG. 3 (2) is a cross-sectional view taken from line XX of FIG. 3 (1). It is.

(E) Operation Using a seamless wound iron core, the finishing accuracy of the joint surface, which is a problem when using a cut core for the iron core, an increase in no-load current due to the superposition of the joint surfaces, and noise reduction It is possible to eliminate the problem of occurrence of generation and the like and to solve the problem of deterioration of the properties of the magnetic material due to residual stress received during mechanical cutting of the wound core. Further, as a coil assembling method of a transformer, for example, a copper plate type one-turn coil 3 of a primary side coil is used.
The thickness per sheet is easily inserted into the seamless core.
It is set in a range that can be fitted to the iron core legs, laminated while inserting the insulator P on the iron core legs, and then, the U-shaped portion 6 of the secondary coil is placed with the insulator P between the primary coils. If the lead-out portions of the primary coil and the secondary coil are electrically connected as described in Section 3. (d) while being interposed and assembled, a large-capacity connection with stable characteristics can be obtained. This is effective in easily and inexpensively manufacturing a transformer using a seamless wound iron core. Although the wound core has been described above, it is a matter of course that the same effect can be obtained even when the coil is mounted on a core having a seamless laminated plate.

(F) Example Another embodiment of the shape of the primary coil and the secondary coil used in the present invention is shown in the drawings.

FIG. 4 is a schematic view of another coil shape used as a primary coil, in which a U-shaped copper plate 10 and a direct coil piece 11 are shown.
A primary copper plate-shaped U-shaped coil 13 having one turn in combination with the above is shown. FIG. 5 is a schematic view of another coil shape used as a secondary coil.
2 shows a turn coil 16 . Therefore, as another embodiment, a copper plate type one-turn coil shown in FIG.
16 , the copper coil 13 shown in FIG.
When the primary coil is combined with a primary side copper plate U-shaped coil 13 shown in FIG. 4 and the secondary coil is a secondary side copper plate U-shaped coil shown in FIG. 2 (2). The case where the transformer is manufactured by combining the mold coils 9 will be described.

That is, in the former, the secondary side copper plate type one-turn coil 16 shown in FIG.
Since the secondary copper plate U-shaped coil 13 is used, the coil insertion method at this time is the same as that of the embodiment described in 3. (d), except that the secondary copper plate type one-turn coil is used first. 16 to the iron core width a of the iron core legs I and II shown in FIG.
Lamination is performed up to about half the height h of the window while interposing the insulator P.

Generally, a secondary coil having a greater thickness than the primary coil is used. In this case, the same shape is used for a single thin copper plate which is easy to insert into the iron core leg. A secondary one-turn coil (not shown) may be prepared, and a plurality of the thin secondary one-turn coils may be stacked to a required thickness.

Next, between the secondary copper plate-type one-turn coil 16 in which the U-shaped portions 10 of the primary copper plate-type U-shaped coil 13 are stacked first, or the secondary copper plate-type one-turn composed of a plurality of sheets coil
The coils can be easily and inexpensively assembled by laminating one by one or a plurality of sheets while interposing the insulator P between them.

After assembling the coils in this way, the U-shaped part 10 of the primary side copper plate type uses linear coil pieces 11 so that each coil is in series, and the secondary side copper plate type one-turn coil 16 is If electrical connection is made so that the coils are parallel in the coil extraction portions 14, 14 ', a transformer can be easily and inexpensively manufactured using a seamless wound iron core.

Next, in another embodiment, that is, in the latter case, the primary side copper plate type U-shaped coil 9 shown in FIG. 4 is used on the primary side, and in this case, FIG. ), Alternately on the iron core legs having a width a, or between the U-shaped portions 10 of the plurality of primary-side copper plate-shaped U-shaped coils 13 of the secondary side copper plate-shaped U-shaped coil 9 . If the character portions 6 are laminated while interposing the insulator P, the primary and secondary coils of the transformer can be laminated easily and inexpensively between the heights h of the windows of the seamless wound iron core. . Then, the primary side copper plate U-shaped coil
13 coil pieces 11 and the primary side coils are connected in series in the same manner as described above, and the L-shaped coil pieces 7, 7 'of the secondary side copper plate U-shaped coil 9 are connected. If the secondary side coils are electrically connected so as to be connected in parallel, a transformer can be manufactured easily and at low cost.

(G) Effects of the present invention As described above, the present invention is for assembling and manufacturing a transformer by laminating a copper plate type primary and secondary coil on a seamless wound iron core with an insulator interposed therebetween. When assembling the transformer, no special equipment is required, and a large-capacity transformer can be manufactured easily and at low cost.

After all, since a seamless wound iron core is used as the core of the transformer, to improve the processing accuracy of the butt joint surface, which was a problem that occurred when using a cut core that has been widely used in the past. Means and processing are not required at all.

In addition, there is no problem of geometrical deformation of the shape of the outer periphery of the cut surface for manufacturing the cut core, and furthermore, there is no problem such as a decrease in magnetism of the iron core material due to residual stress generated at the time of cutting. Noise, increased no-load current, or
A good product with stable transformer characteristics without deterioration in magnetic characteristics can be obtained.

By the way, in the transformer using the seamless iron core manufactured according to the present invention, compared to the transformer manufactured using the conventional cut core, the noise generated during the operation of the transformer is not generated at all, and the no-load current is not generated. It has been found that the current value can be reduced to about 1/2 or less of the conventional value, and that the characteristics of the transformer operate stably.

Therefore, the present invention is effective in easily and inexpensively manufacturing a transformer having good characteristics and solving various problems that have occurred when manufacturing using a conventional cut core.

Although the present invention has been described by using a wound core, a structure having a seamless laminated core is also possible, and is not limited to a method of manufacturing a large-capacity transformer. Is also valid.

[Brief description of the drawings]

FIG. 1 shows an embodiment of the present invention. FIG. 1 (1) shows a case where a primary copper plate type one-turn coil is laminated on an iron core leg of a transformer with an insulator interposed therebetween. FIG. 2 (1) shows that a U-shaped coil of a secondary side copper plate was laminated while interposing an insulator between the primary side coils. FIG.
Secondary copper plate type one-turn coil shape schematic diagram, FIG. 2 (2) is a secondary side copper plate U-shaped coil shape schematic diagram, FIG. 3 (1)
Is a drawing of the iron core when using two seamless cores,
FIG. 3 (2) is a cross-sectional view of the wound core taken along the line XX of FIG. 3 (1), FIG. 4 is a schematic view of a primary coil used in another embodiment, and FIG. FIG. 7 is a schematic diagram of a secondary coil used in another embodiment. 1,2 ... Seamless wound core, 3 ... Primary side copper plate type 1 turn coil, 4,4 '... Primary side copper plate type 1 turn coil drawer, 5 ... Primary side copper plate type 1 turn Coil opening, 6 ...
U-shaped part of secondary side copper plate U-shaped coil, 7,7 '……
L-shaped secondary side copper plate U-shaped coil extraction coil piece, 8
... Secondary copper plate U-shaped coil opening, 9 ... Secondary copper plate U-shaped coil, 10... Primary copper plate U-shaped portion, 11... Primary copper plate Linear coil piece of U-shaped coil, 12 ... Opening of primary copper plate U-shaped coil, 13 ...
… Primary side copper plate type U-shaped coil, 14, 14 '… Secondary side copper plate type one-turn coil lead-out part, 15… Secondary side copper plate type one-turn coil opening, 16 …… Secondary side copper plate Type turn coil, I,
II ... Seamless wound iron core leg, P ... Insulator, a ... 2
Width of iron core legs, b: thickness of iron core, h: height of window.

Claims (3)

(57) [Claims] 1. A seamless iron core, and a copper plate type coil used as a primary side coil and a secondary side coil wound around the iron core leg thereof,
A method for manufacturing a transformer, comprising laminating and assembling insulators within a predetermined height of a window of an iron core with an insulator interposed therebetween. 2. The transformer according to claim 1, wherein the primary side coil of the transformer is a single turn or a copper plate type coil having a U-shaped copper plate and a straight coil piece combined to make one turn.
13. The method for manufacturing a transformer according to claim 1. 3. The secondary coil of the transformer is a single turn or a combination of a U-shaped copper plate and two L-shaped coil pieces.
Claim 1 using a copper plate type coil as a turn
13. The method for manufacturing a transformer according to claim 1.