KR870000949B1 - Toroidal core electromagnetic device - Google Patents

Abstract

The arrangement is useful in inductor, transformer, motor or generator. The core is formed from stacked toroids, each of a magnetically permeable strip material, preferably, an alloy of composition M(60-90)T(0-15)x(10-25) where M is iron, cobalt or nickel, T is a transition metal element, and X is phosphorous, boron or carbon. The number of primary coil sections is at least three, and is in the range of 16-20. A segmented secondary winding is formed of inner conductors and outer conductors seperated by annular spacers.

Description

Annular core electromagnetic device

1 is an isometric view of the present electromagnetic device cut out for illustration.

2 is a cross-sectional view of the electromagnetic field.

3 is a perspective view of a winding removed from the electromagnetic device of FIG.

4 is a partial system explanatory diagram of the secondary winding of the present electromagnetic device of FIG.

5 is a system explanatory diagram of a secondary winding of the present electromagnetic device of FIG.

6 is a perspective view of one of the primary coils of the present electromagnetic device of FIG.

7 is a structural explanatory diagram of a connection in a primary coil of the present electromagnetic device of FIG.

8 is a side view of another linker and jumper, which is a variation of the linker shown in FIG.

9 is a front view of the assembled transformer.

10 is a structural diagram of a secondary winding.

The present invention relates to an electromagnetic device used in an electromagnetic induction device such as an inductor, a transformer, a motor, a generator, and the like. In the manufacture of conventional shell-type transformers, the iron core material is cut, the windings are wound, and the cutting parts are bonded again, but the problem thereof is to cut and mold the iron core material without deteriorating its magnetic properties.

A core transformer was proposed to solve this problem, but it was too bulky and inefficient in terms of material use. Furthermore, in the transformer of the type described above, the heat generated by the winding or the iron core during operation often causes a temperature rise of 50 ° C or higher, thereby increasing the deterioration rate of the solid insulating material in the iron core or the winding, It also increases the degradation rate of the liquid coolant contained. For these reasons, the transformers of the type described above are expensive to produce and maintain and have low efficiency.

Accordingly, the present invention seeks to provide an electromagnetic device that is lighter, harder, easier to assemble, and more effective and reliable in operation than a shell or core type transformer.

Overall, the apparatus includes a magnetic core having a closed trunk with a central opening and a primary winding having at least three primary coil sections arranged around the core surrounding the trunk.

In addition, the present invention provides a method of forming a magnetic core having a closed trunk with a central opening, and winding a high investment material into multiple layers, and a plurality of electrically conductive materials surrounding the trunk to form a primary coil section. A method of manufacturing an electronic device, the method comprising: winding a layer of over a core to a core and winding at least second and third primary coil sections over the core in the same manner.

The present invention further provides an electromagnetic device having a secondary winding in a segmented form. This segmented secondary winding contains several ring connections that surround the coil and primary coil section and are connected to provide a spiral current path. Each ring connector has a portion passing through the central opening of the coil and is located near its circumference.

The device of the present invention has a remarkable shape modification.

The annular core requires less material for a given capacitance.

Since the iron core does not have an air gap, the magnetization current is reduced. The annular core is easily wound from the strip material and it is particularly preferable to use an amorphous metal plate.

Loops are easily manufactured or cast and press-fit during assembly to strengthen the device and form an outer cover that protects the core and the windings in it.

The arrangement divided into sections of the primary and secondary windings lowers the temperature increase due to heat loss.

As a result, the electromagnetic device of the present invention has a smaller size, less weight, lower cost, higher efficacy and reliability than conventional electromagnetic devices. Then, the detailed description of the present invention will be described with reference to the drawings.

In FIG. 1, an electronic device suitable for operating as a transformer having a 25 KVA rating is shown, although other ratings may be expected.

The magnetic iron core 10 has an annular body 12 in which several pieces are stacked.

Each annulus 12 is formed of a permeable strip material wound around a coil. As you can see, the seven rings are stacked, each about 1 inch high, about 8.6 inches (21.8 cm) inside, and 14.3 inches (36.32 cm) outside.

However, the number of layers, height, and diameter of the annular body can be changed according to the required efficacy, the requirement for reducing the volume and coins, power rating, frequency, and the like.

The annular body 12 is separated by the annular insulator 14, which is mainly 130 ° C, such as thermoplastic or thermosetting plastic, glass fiber, glass fabric, polycarbonate, MICA'CAPTAN'LEXAN, and the like. These are those having the flexibility, dielectric strength, viscosity and stability required at the operating temperature of the magnetic core. The insulating layer 14 is in the form of a flexible film and has a thickness of about 1/2 Mil (1.27 × 10 ⁻³ MM), the inner diameter and the outer diameter substantially coincide with the annular body 12.

The insulating layer 14 does not necessarily need to be continuous and may be in the form of elements with a predetermined interval if necessary. The insulating layer may be sprayed or treated with paint or the like without being separated.

In addition, the iron core 10 may be deformed into an egg shape, a rectangle, an angular shape, or the like instead of an annular shape.

Similar insulation packaging 16 is shown in the figure, the iron core 10 is surrounded from the outside and surrounded by an insulating cocoon (insulating cocoon).

The plate material on which the coil of the annular body 12 is wound is magnetically soft material. Such a material preferably has the following properties.

a) low hysteresis loss

b) low eddy current loss

c) low coercive force

d) high permeability

e) high saturation

f) less change in permeability due to temperature

As long as it has a magnetically soft strip form such as high purity, iron, silicon, iron / nickel alloys, iron / cobalt alloys, etc., which are generally used, all are suitable for practical use of the present invention.

Particularly good, however, are the amorphous (glassy) magnetic alloys used in recent years.

These alloys have at least 50% amorphous by X-ray diffraction.

These alloys include alloys having the general formula M _{60_90} T _{_15} X _{10_25.}

Wherein M is at least one of iron, cobalt and nickel, and X is at least one of a metalloid element of phosphorus, boron and carbon.

And T is at least one of the transition metal elements.

Up to 80% of X, carbon, phosphorus, and / or boron may be substituted with aluminum, antimony, beryllium, germanium, indium, silicon, tin.

These amorphous metal alloys used as iron cores of magnetic devices have properties that are superior to those of polycrystalline alloys generally used.

Such amorphous alloy plate preferably has at least 80% amorphous, more preferably 95% amorphous.

Amorphous self alloys of the iron core 10 can be obtained by cooling the application at a rate of 10 ⁵ -10 ⁶ ° C per second.

By using well-known technology, it is possible to make quench continuous plates. When used for the magnetic core of an electromagnetic induction device, the strip material of the iron core 10 typically takes the form of a lead or ribbon.

This strip material can be easily obtained by applying the melt directly to a cold surface or into a kind of cooling medium. This process technology significantly lowers the manufacturing cost.

This is because no wire drawing or ribbon forming process is required.

The amorphous metal alloy constituting the iron core 10, depending on the specific structure, has a high tensile strength of about 100000-600000 psi (1.38 × 10 ⁶ -4.14 × 10 ⁶ Kpa).

This can be compared with the tensile strength of about 40000-80000 psi (2.76 × 10 ⁶ -5.52 × 10 ⁶ Kpa) of the polycrystalline alloy used in the annealing condition.

High tensile strength is very important when the centrifugal force is large, such as iron cores in motors and generators.

Because strong alloys withstand high rotational speeds. In addition, the amorphous metal alloy used to make the iron core 10 has a very high electrical resistance of 160-180 microhm-cm (1.6-1.8 microhm-eters) at 25 ° C, due to the specific structure. Conventional conventional materials have an electrical resistance of about 45-160 microhm-cm (0.45-1.6 microhm meters).

The high resistivity of the amorphous metal alloys defined above is useful for minimizing the vortex current in AC applications and reducing the core core loss.

Another advantage of using an amorphous metal alloy to form the iron core 10 is that the coercive force is lower than that of the previous configuration of the same metal capacity, so that iron which is relatively inexpensive compared to relatively expensive nickel is more iron core (10). It can be used for. Each of the annular bodies 12 (not shown) is achieved by winding successive turns on the mandrel, which keeps the strip material under tension, for a firm effect. The number of turns is determined by the required size of each annulus 12.

The thickness of the strip material of the annular body 12 is preferably 1-2 mils (2.54 × 10 ⁻² -5.08 × 10 ⁻² mm). Due to the relatively high tensile strength of the amorphous alloy used here, 1-2 mils thick strip material can be used without risk of fracture.

Relatively thin strip materials have a higher effective resistance because the boundary through which the vortex current must pass is greater per unit of radial length.

The primary windings are arranged at intervals with at least three primary coil sections 18 surrounding the trunk of the iron core 10 as shown here.

The specific design shown here includes eighteen coils 18 formed of 84 turns- of insulated aluminum plates with a thickness of about one inch wide (2.54 cm) and 0.005 inches (0.013 cm). Although other ratings are expected, this arrangement can add 6000 volts to the primary.

The number of primary coil sections 18 introduced here depends on the internal diameter of the coil 10, the width and thickness of the strip material used in the coil sections, the number of turns per section, and the requirements between the sections. It may vary depending on the interval.

Preferred number of primary coil sections is about 10-30, more preferably about 16-20.

In addition, the coil 18 may vary in dimensions depending on the voltage, power rating, and use space, and the cross section may also be changed into a circular, square or other shape.

The annular spacers 20 and 21 shown on both sides of the coil 18 may be formed of a suitable insulating material having mechanical strength and dielectric strength sufficient to withstand the environment surrounding the transformer.

The above-described materials used for the phenol resin or the insulating layer 14 may be used for the spacers 20 and 21.

Each of the inner and outer diameters of the spacers 20 and 21 should be sufficient to cover the coil 18. 18 ribs 23 are provided around the spacers 20 and 21.

As shown next, the spacers 20 and 21 are identical, and there is a series of notches arranged at an angle between the inner and outer circumferences to arrange the secondary windings.

This will be explained later in detail.

It will be appreciated that the electromagnetic device of the present invention may be used in inductance without secondary windings, or in transformers or other electronic devices using secondary windings.

The electromagnetic device in the present invention has a secondary winding in which each part is divided into a fan shape as indicated by winding several internal conductors 22 and external conductors 24.

Conductors 22 and 24 are separated by spacers 26 and 27 on either side of conductor 22.

The spacers 26 and 27 are formed of an insulating material similar to the spacers 20 and 21 and the outer and inner diameters are sized appropriately for the inner space of the conductor 24.

The conductors 22 and 24 form a spiral winding and one terminal of the conductor 24 is an induction wire 28 as shown.

3 shows a perspective view of the conductors 22 and 24.

As shown, the conductors 22 and 24 are separated from their magnetic cores and unfolded to explain the internal details. Conductors 22 and 24 are made of aluminum and provide a spiral current path.

This current path is formed from a connection consisting of the lower end 30 and the first leg 3 2 and the second strut 34, which appear to be “U” shaped here.

The struts 32 and 34 are 1/2 inch (1.27 cm) in diameter, and the lower end 30 has a rectangular cross section of 1 inch (2.54 cm) high and 1/2 inch (1.27 cm) wide. And the cross section may vary depending on the current rating. The circuit of conductor 22 is affected by jumpers 36 connecting struts 32 and 34.

The struts 32 and 34 are tapered at both ends so as to fit into the holes 37 at the ends of the portions 30 and 36.

Preferably, each end and hole 37 of the legs 32 and 34 has essentially the same sharpness so that the contact area and the contact pressure of the abutting surface are maximized there.

These joints may be keyed or serrated to improve electrical conductivity and mechanical precision.

Conductor 24 consists of a lower end 42, a first strut 44 and a second strut 46, each having the same cross section as (30), 32, 34. However, the length is different. Is selected so that the conductors 22 fit around the spacers 20 and 21 and the conductors 24 fit around the spacers 26 and 27.

In this embodiment the lower ends 30 and 42 may be aligned in line and are relatively shorter than their corresponding jumpers 36 and 40.

The connection between the conductors 22 and 24 is made as a vertical bar 38 with a median length of the struts 34 and 46.

This length is such that the upper end of the rod 38 is flush with the strut 46 of the conductor 24 and the conductor 24 fits around the beginning of the conductor 22 (not shown here). nested structure).

Leg 46 may be wrapped with insulation to prevent shorting between adjacents of conductor 24.

4 and 5, the secondary winding of FIG. 3 is illustrated. 4 depicts a spacer 20, including inner notches 50 and outer notches 52, evenly positioned at an angle. Secondary column 34 lies along inner circumference 51, while secondary column 46 lies along innermost circumference 56.

Upper jumpers 36 and 40, indicated by solid lines, and lower ends 30 and 42, indicated by dotted lines, influence the connection described above. The above-described structure can be more easily understood as shown in FIG. 5, which diagrammatically wraps the inner (or primary) conductors 22 spirally wound around the iron core 10 and connected to the output terminals 60 and 61. Shows.

The outer (or secondary) conductor 24 is also spirally wound around the iron core 10 and further connected to the terminals 62 and 63 and the center tap 64. For example, the spiral of the conductor 22 is made by a leg 34a that connects to the portion 30a that descends and extends outward and then connects the leg 32a and the jumper 36a.

The jumper 36a is connected to the next connecting hand, i.e., the strut 34b. This proceeds in this form and describes one complete turn around the entire iron core.

The helical formation of the outer conductor 24 can be understood by looking at the inner leg 46a which is connected to the lower body 42a and connects the outer leg 44a therefrom. Jumper 40a is connected to leg 46b.

The foregoing description describes one completed turn-on covering iron core and winding 22.

The inner circumference 46 is in contact with and in contact with the inner circumference 34.

The latter is adapted to the connection between the adjacent of struts 46. However, the strut 34 is layered and separated and the strut 46 has an insulator so that there is no short circuit between the turns.

The secondary windings described above have separate windings 22 and 24, each with 26 turn-turns and each producing a voltage of 120 volts at 60 Hz (240 volts in total).

Of course, other output voltages or frequencies are possible. Like items 30, 32, and 34, items 38, 42, and 44 are preassembled, and items 30, 32, and 34 are notches 50 and 52, respectively. Assembled to fit.

The jumpers 36 are thus positioned across the appropriate struts 32 and 34 and individually or simultaneously seated.

Similarly elements 38, 42, 44 are fitted into or in close proximity to adjacent notches 50, 52, with jumpers 40 positioned across struts 44 and 46 and individually or simultaneously. Is set in place. Optionally, as shown in FIG. 10, the layered secondary coils may comprise a plurality of wound ribbon sections connected in series and in parallel.

In general, the number of sections is 10-30, and the number of turns of the ribbon used in each section is 10-100. The ribbon width is 0.5-3cm and the ribbon thickness is 0.025-2cm.

In the practice of FIG. 10, twenty-two turns and twenty sections each are wound with a ribbon 1/2 inch wide (1.27 cm) and 0.04 inch (1.1016 cm) thick. Twenty sections are connected in series. In the practice of FIG. 10, ten sections are placed parallel to each other with a cross section of 0.2 inches (0.508 cm).

6 and 7 illustrate the primary coil of the transformer of FIG. 6 shows that each coil 18 constitutes a separating bobbin 70 wound around an aluminum plate 72. The use of this bobbin 70 is optional because the individual coils 18 can support themselves.

The strip 72 has an insulating layer 74 to prevent shorting between adjacent turns.

The connection to the coil 18 is made via the inner end 76 and the outer end 78 of the strip 72.

The bobbin is essentially a canal with a rectangular track and has a central hole sized to fit the core.

In this embodiment 18 coils are used, each having 84 turn-turns of strip material 72.

Thus, for a primary voltage of 6000 volts, each coil has a voltage drop of approximately 333 volts. However, the potential difference between the first and last is 6000 volts and if adjacent, there is a design limitation.

Therefore, the coils 18 are preferably wired and grouped uncontinuously as shown in FIG. As shown here, the coils 18 are grouped into four quadrants (80, 82, 84, 86) and the coils in each quadrant are connected to structurally couple their voltages.

The coil 18 of the quadrant 80 is connected between the terminal 88 and the induction wire 90.

Coil 18 of quadrant 86 connects between 90 and 92.

Quadrant 84 connects between 90 and 92 and coil 18 of quadrant 82 is connected between terminal 94 and induction wire 96.

All these connections mentioned above result in the structural coupling of the voltage in each quadrant.

The highest potential difference between the terminals of the coil 18 is between the terminals 96 and 86. However, they are spaced about 180 ° apart.

Therefore, there is no excess electric field which leads to dielectric breakdown. Moreover, each coil 18 has 84 turns-turned down by 333 volts. The interlayer potential between each turn in the coil 18 is only 4 volts. This suitable potential difference can be easily adjusted by the insulating layer 74.

In a specific implementation consisting of a conventional layer of a large number of terminal-on insulated wires that coil 18 commonly uses, the potential difference between successive layers will be relatively large.

The electromagnetic device described above is a distribution transformer having a load loss of 240 watts at a capacity of 24 KVA and a total weight of 360 lbs (163.3 kg) including the cooling oil of the case. With a 165lbs (74.8kg) weight and an amorphous alloy core operating at 13.5Kilogauss, the core loss is only 16 watts.

On the other hand, distribution transformers of the same capacity and the same load loss using the conventional cross design with the same amorphous alloy at the same flex density are a total of 720 lbs (326.5 kgr). The core is about 260 lbs (117.9 kg) and the core loss is 38 watts.

Typical 25KVA voltage transformers have silicon-iron cores operating at 16-17 kilograms, load losses of 300-500 watts, and core losses of 90-113 watts.

Due to the utility's efforts to scale down for less core loss and less load loss, the transformer in a 25KVA design using the latest transformer, the highest quality grain array silicon-iron core, weighs 400 lbs. 181.44Kgr) with a core loss of 88 watts and a load loss of about 250 watts.

In contrast to these, it is clear that the transformer made by the present invention is excellent in terms of economy and efficiency.

In FIG. 8, another link 100 and jumper 102 are shown.

The connecting hand 100 is a circular taste bar formed in a "U" shape bent at a right angle.

Both ends 104 and 106 have inward teeth or teeth as shown in the figure. The ends 104 and 106 are designed to fit the holes 108 and 110 of the jumper 102. The jumper 102 is a “U” shaped bracket, which is not hollow here in the hemisphere, but may be made of a perforated tube in some specific expressions. The jumper 102 may be replaced with the jumper 36 or 40 of FIG. 3 with appropriate dimensions.

The connection hand 100 may be replaced by a connection hand consisting of (30, 32, 34) or a connection hand consisting of (4 2), 44, 46 properly adjusted. In other embodiments, the connection of the connecting hand 10 0 and the jumper 102 may be effected with suitable fasteners such as bolts or nuts.

The finished product is shown in FIG. 9, in which the transformer of FIG. 1 is indicated by dashed line as part 112. FIG.

The part 112 has an effectively strong metal skeleton, i.e. the conductors of (22) and (24) of FIG. 1, which is very resistant to shock. The part 112 is installed inside the body 114 and is filled with a cooling medium such as oil.

Since the transformer 112 is a relatively open structure that exposes most of the iron wire 10, cooling is very well promoted, and in particular there is sufficient space between the coils 18 of FIG. It can be directly in contact with the iron core (10) through.

The primary connection of high voltage is made by terminals 118 and 120 located on top of the high voltage insulators 122 and 124.

Insulators 122 and 124 are located on lid 128 and are connected to transformer 112 via an internal conductor that is not visible here.

The lid 128 seals the fuselage 114 and prevents oil from leaking inside the fuselage.

The secondary connection is indicated by output terminals 130, 132, 134, which corresponds to (62) (64) 60 of FIG.

The assembly of FIG. 9 is relatively low because the transformer is annular.

Arresters 136 and 138 can carry dangerous overvoltages from terminals 118 and 120 to the grounded fuselage 114.

The above-described implementation functions in various modifications.

The current voltage rating can be modified by varying the number of turns in size and winding.

By changing the shape of the container can be used for home use. The continuity for the connecting primary windings can be changed, especially for voltage applications.

Cooling oils are mentioned in some embodiments, which may be replaced with other liquids, gas coolants, and the like.

The primary winding is shown as being obscured by the secondary winding, but this winding arrangement can be changed in other embodiments.

Furthermore, the first and second functions can be changed.

The various fixtures used to support and insulate the windings may use different shapes and materials depending on the required dielectric ectric strength, weight, and the resulting structural configuration. Although aluminum conductors are described here, other conductors may be used depending on weight, resistivity and other requirements.

Claims (10)

A magnetic core having an enclosed trunk defining a hollow part, at least three primary coil sections formed by enclosing an electrically conductive strip having an insulating layer on one side thereof with the outer periphery of the trunk, radially arranged around the core A primary winding configured as a primary winding, and a secondary winding configured by radially arranging a plurality of kraft links that are interconnected to form an electric path through the hollow portion of the iron core to form an electric passage winding, and the cleft links are each composed of a series of U-shaped members each consisting of a first post, a second post, and a lower end such that the first post of each member is formed by jumpers having inclined holes. An electron, characterized in that it is connected to a second post of the next member to form a continuous electric passage Device. An electromagnetic device according to claim 1, wherein said iron core has an annular, ie annular structure. The device of claim 1, wherein the primary winding portion is comprised of 10-30 primary coil sections. The device of claim 2, wherein the iron core consists of a plurality of layers of insulated permeable strips. Electromagnetic device according to claim 4, characterized in that the permeable strip material is composed of a metal alloy _having a composition of general formula M _{60_90} T _{0_15} X _{10_25} and at least 50% amorphous (amorphous). Is at least one of iron, cobalt and nickel, T is at least one of the transition metal elements, and X is one of the base metals of phosphorus, boron and carbon. (delete) 2. The device of claim 1, wherein the iron core consists of an annular body, in which a plurality of non-insulated permeable strip materials are wound in coil form. The electromagnetic device according to claim 1, wherein spacers having a plurality of notches into which secondary windings are fitted are configured on the iron core. An assembly manufacturing method of an electromagnetic device, comprising the following steps. (a) Winding several layers of permeable strip material to form a magneti-coore with a closed trunk defining the hollow part. (b) surrounding the iron core, surrounding the trunk through the hollow part, surrounding the conductive material in several layers to form a primary coil section. (c) forming at least three primary coil sections formed as described above radially around said iron core to form a primary winding. (d) Surrounding the iron core with a secondary winding with a plurality of kraft links consisting of a U-shaped member each comprising two posts. (e) Arranging the cleft links radially around the primary winding. (f) interconnecting the upper and lower ends of one post of each link with the other post of the next link. (delete)

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