NZ624461B2 - Wind-on core manufacturing method for split core configurations - Google Patents
Wind-on core manufacturing method for split core configurations Download PDFInfo
- Publication number
- NZ624461B2 NZ624461B2 NZ624461A NZ62446112A NZ624461B2 NZ 624461 B2 NZ624461 B2 NZ 624461B2 NZ 624461 A NZ624461 A NZ 624461A NZ 62446112 A NZ62446112 A NZ 62446112A NZ 624461 B2 NZ624461 B2 NZ 624461B2
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- New Zealand
- Prior art keywords
- core
- transformer
- legs
- winding
- end legs
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title description 12
- 239000011162 core material Substances 0.000 claims abstract description 102
- 238000004804 winding Methods 0.000 claims abstract description 64
- 239000004020 conductor Substances 0.000 claims abstract description 11
- 238000003475 lamination Methods 0.000 claims abstract description 4
- 238000005452 bending Methods 0.000 claims abstract description 3
- 238000005520 cutting process Methods 0.000 claims abstract description 3
- 238000009413 insulation Methods 0.000 claims description 7
- 239000000463 material Substances 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 4
- 230000005294 ferromagnetic Effects 0.000 claims description 2
- 239000002184 metal Substances 0.000 claims description 2
- 229910052751 metal Inorganic materials 0.000 claims description 2
- 230000001808 coupling Effects 0.000 claims 8
- 238000010168 coupling process Methods 0.000 claims 8
- 238000005859 coupling reaction Methods 0.000 claims 8
- 238000000034 method Methods 0.000 description 4
- 238000009826 distribution Methods 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 2
- 238000000137 annealing Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000006011 modification reaction Methods 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 238000010079 rubber tapping Methods 0.000 description 1
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
- H01F1/153—Amorphous metallic alloys, e.g. glassy metals
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F7/00—Magnets
- H01F7/06—Electromagnets; Actuators including electromagnets
- H01F7/08—Electromagnets; Actuators including electromagnets with armatures
- H01F7/081—Magnetic constructions
- H01F2007/083—External yoke surrounding the coil bobbin, e.g. made of bent magnetic sheet
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/245—Magnetic cores made from sheets, e.g. grain-oriented
- H01F27/2455—Magnetic cores made from sheets, e.g. grain-oriented using bent laminations
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/02—Cores, Yokes, or armatures made from sheets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/04—Cores, Yokes, or armatures made from strips or ribbons
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0213—Manufacturing of magnetic circuits made from strip(s) or ribbon(s)
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0213—Manufacturing of magnetic circuits made from strip(s) or ribbon(s)
- H01F41/0226—Manufacturing of magnetic circuits made from strip(s) or ribbon(s) from amorphous ribbons
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0233—Manufacturing of magnetic circuits made from sheets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/061—Winding flat conductive wires or sheets
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49071—Electromagnet, transformer or inductor by winding or coiling
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49075—Electromagnet, transformer or inductor including permanent magnet or core
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49075—Electromagnet, transformer or inductor including permanent magnet or core
- Y10T29/49078—Laminated
Abstract
method provides a portion of a transformer (10) by forming a core (12) by providing transformer core material, cutting individual laminations (20) and bending each individual lamination them into generally C-shaped members, stacking some members to define a first core portion (16) having a main leg and two opposing end legs, stacking other members to define a second core portion having a main leg (22) and two opposing end legs (24, 26), arranging the main legs in a back-to-back manner to define the core having a core leg defined by the two main legs, and opposing core yokes, defined by the end legs. Conductive material is wound directly around the core leg to form a primary winding and secondary winding in any order of arrangement, thus providing a first transformer portion. The transformer portion may be part of a single transformer or, when second and third transformer portions are provided, as part of a three-phase transformer. g and two opposing end legs, stacking other members to define a second core portion having a main leg (22) and two opposing end legs (24, 26), arranging the main legs in a back-to-back manner to define the core having a core leg defined by the two main legs, and opposing core yokes, defined by the end legs. Conductive material is wound directly around the core leg to form a primary winding and secondary winding in any order of arrangement, thus providing a first transformer portion. The transformer portion may be part of a single transformer or, when second and third transformer portions are provided, as part of a three-phase transformer.
Description
WIND-ON CORE MANUFACTURING METHOD
FOR SPLIT CORE CONFIGURATIONS
FIELD
The invention relates to power distribution transformers and, more particularly, to
method of manufacturing a split core configuration with primary and secondary
windings wound directly thereon.
BACKGROUND
Conventionally, the core manufacturing process and the coil manufacturing
process for distribution transformers are separate, with the cores and coils being
assembled at a later stage. To facilitate this, the cores and coils are produced to
a set of standard sizes to simplify manufacturing and to reduce the amount of
core tooling required. As a result of this standardization, it is not possible to
optimize both the core and coil configurations fully. This leads to increased
cost and loss of competitiveness.
Thus, there is a need to provide fully flexible core configurations at similar
output speeds to existing wound core technology.
SUMMARY
An advantage of the invention is to fulfill the need referred to above. In
accordance with the principles of an embodiment, this advantage is achieved by
a method of providing a portion of a transformer. The method forms a core of the
transformer by providing transformer core material, cutting individual laminations
and bending each individual lamination into generally C-shaped members,
stacking a first plurality of the bent C-shaped members to define a first core
portion having a main leg and two opposing end legs, stacking a second plurality
of the bent C-shaped members to define a second core portion having a main leg
and two opposing end legs, and arranging the main legs of the first and second
6249551_1 (GHMatters) P96993.NZ TERUNI
core portions in a back–to-back manner to define the core wherein a core leg is
defined by the two main legs of the first and second core portions, and opposing
core yokes are defined by the end legs of the first and second core portions.
Conductive material is wound directly around the core leg to form a primary
winding and secondary winding in any order of arrangement, thus providing a first
transformer portion. The first transformer portion may be part of a single
transformer or, when second and third transformer portions are provided, as part
of a three-phase transformer.
Other advantages, features and characteristics of the present invention, as well
as the methods of operation and the functions of the related elements of the
structure, the combination of parts and economics of manufacture will become
more apparent upon consideration of the following detailed description and
appended claims with reference to the accompanying drawings, all of which form
a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood from the following detailed description of
the preferred embodiments thereof, taken in conjunction with the accompanying
drawings wherein like numbers indicate like parts, in which:
is a view of a portion of a transformer provided in accordance with an
embodiment.
is a view of core portions of the transformer portion of
is a view of a core of the transformer portion of
is a view of conductive sheet being wound together with an insulating
sheet in accordance with an embodiment.
is a view of a single phase transformer of an embodiment.
6249551_1 (GHMatters) P96993.NZ TERUNI
is a view of one transformer portion being coupled to another transformer
portion in accordance with an embodiment of providing a three-phase
transformer.
is a view of a three-phase transformer of an embodiment.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
The embodiment relates to a manufacturing method for single and three-phase
core and shell type distribution transformers. Thus, with reference to
there is shown a perspective view of a portion of a single phase transformer,
generally indicated at 10, containing a core configuration, generally indicated at
12, embodied in accordance with the present invention. The core 12 is
comprised of two core portions 16 and 18, as explained below. The transformer
portion 10 comprises a winding assembly 14 mounted to the core 12.
With reference to to form each core portion 16 and 18, first, transformer
core material such as a sheet of ferromagnetic metal is provided. Individual
laminations 20 are cut from the core material. Each lamination 20 is bent into a
generally C-shape and certain of these laminations 20 are stacked to define the
first core portion 16 having a main leg 22 and two opposing end legs 24, 26.
The main leg 22 has a back surface 27. Other laminations 20 are stacked to
define the second core portion 18 having a main leg 28 and two opposing end
legs 30, 32. The main leg 28 has a back surface 29.
Referring to the back surfaces 27 and 29 of the respective main legs 22
and 28 are arranged to contact in a back-to-back manner to define the core 12
having a core leg 34 defined by the two main legs 22, 28, and opposing core
yokes, generally indicated at 36 and 38, with yoke 36 defined by end legs 24 and
and yoke 38 defined by the end legs 26 and 32. The back surfaces 27 and 29
may be coupled or joined. The core 12 is preferably formed on a conventional
Unicore producing machine manufactured by AEM Unicore by modifying the
6249551_1 (GHMatters) P96993.NZ TERUNI
programming thereof, or by a machine specifically configured for forming the core
After the core 12 is formed the core 12 is moved to a winding machine and
conductive material such as copper is wound directly about the core leg 34 to
define the winding assembly 14 (. In particular, the winding assembly 14
includes a low voltage winding 44 and a high voltage winding 46. Two separate
machines can be used to wind the low voltage winding 44 and the high voltage
winding 46. Alternatively, a single, combination machine can be used to wind
both windings 44, 46.
As best shown in FIGs. 1 and 3, slits 40 are provided in the ends 42 the yokes 36
and 38 to facilitate direct winding of the core 12 to form a transformer as will be
described below. The slits 40 define alternating cuts and protrusions 52 (
that extend in a direction transverse with respect to an axis A of the core leg 34.
Thus, moving the slits 40 to the yokes allows winding directly on the core leg 34.
If the slits 40 are in the conventional position, such winding is not possible.
An example of winding the low voltage winding 44 on a machine is as follows:
1) adjust core clamping tool to accommodate correct size of core 12
so that the main legs 22 and 28 are clamped in a contacting back-to-
back manner,
2) mount the core 12 to winding machine,
3) select and load the correct conductive material and insulation
material,
4) program the machine with number of turns/layers for particular
core low voltage winding configuration,
) start process by attaching a first busbar,
6) commence winding by winding conductive material 47 and
insulation material 49 ( simultaneously (as disclosed in U. S.
Patent No. 6,221,297, the content of which is hereby incorporated by
reference into this specification),
7) throughout the winding process insert cooling ducts 48 (
6249551_1 (GHMatters) P96993.NZ TERUNI
and insulation barriers as required,
8) at appropriate program position, attach the second busbar,
9) finalize the low voltage winding 44 and secure it with tape, and
) remove the core 12 with low voltage winding 44 from the machine
(if separate winding machines are use).
If two winding machines are used, the core 12 with low voltage winding 44 is then
moved to a high voltage winding machine and the winding of the high voltage
winding 46 is as follows:
1) adjust the core clamping tool to accommodate correct size core 12
2) mount core 12 (now with low voltage winding 44) to the machine,
3) select and load correct conductor material and insulation,
4) program the machine with the number of turns/layers for particular
design,
) commence winding (conductive material and insulation material
simultaneously as above) over the low voltage winding 44,
6) throughout the winding process insert cooling ducts and insulation
barriers as required,
7) at appropriate program position, create electrical tapping points as
required,
8) finalize the low voltage winding 46 and secure it with tape,
9) remove the core 12 with windings 44, 46 from the machine.
In the embodiment, it is noted that the high voltage winding 46 is wound upon the
low voltage winding 44. However the order of winding and number of windings is
not critical so long as at least a primary and secondary winding are formed. If the
transformer is a step-down transformer, the high voltage winding 46 is the
primary winding and the low voltage winding 44 is the secondary winding.
Alternately, if the transformer is a step-up transformer, the high voltage winding
46 is the secondary coil and the low voltage winding 44 is the primary winding.
With reference to complete a single phase transformer, generally
indicated at 45, C-shaped side legs 50 (see Fig. 6) are coupled to the yokes 36,
6249551_1 (GHMatters) P96993.NZ TERUNI
38 using the slits 40 and protrusions 52 defined in the ends thereof that
cooperate with the slits 40 and protrusions of the end legs of the yokes 36, 38.
The assembly of the side legs 50 is best explained with reference to FIGs. 6 and
7, where a three-phase transformer, generally indicated at 51, is formed. With
reference to three transformer portions are formed by the method
described above. Two transformer portions 10 and 10’ are shown ready
to be coupled together. Thus, transformer portion 10’ is moved so that
protrusions 52’ in the end legs of the core portion 16’ engage slits 40 in the end
legs of the core portion 18 of the transformer portion 10, and protrusions 52 of the
end legs of the core portion 18 of the transformer portion 10 engage slits 40’ in
the end legs of the core portion 16’ of the transformer portion 10’. As shown in
a third transformer portion 10” is coupled to end legs of the core portion
16 of the transformer portion 10 in the same manner. Finally, a C-shaped side
leg 50, also having the slits 40 and protrusions 52, is coupled to core portion 18’
of the transformer portion 10’ and to core portion 16” of the transformer portion
” using the slits and associated protrusions thereof.
With the method of the embodiment, the windings 44 and 46 are wound directly
onto the core leg 34 after manufacturing of the core 12 to reduce manufacturing
time. The method also allows complete optimization of the core 12 and winding
configuration to reduce material cost. It is also possible to eliminate the core
annealing process using this method of core manufacture. The method further
significantly improves manufacturing throughput, reduces labor, improves quality,
and reduces OHS risks. The method allows wind-on core (WOC) leg for
transformers traditionally manufactured using wound core technology.
The foregoing preferred embodiments have been shown and described for the
purposes of illustrating the structural and functional principles of the present
invention, as well as illustrating the methods of employing the preferred
embodiments and are subject to change without departing from such principles.
Therefore, this invention includes all modifications encompassed within the spirit
of the following claims.
6249551_1 (GHMatters) P96993.NZ TERUNI
It is to be understood that, if any prior art publication is referred to herein, such
reference does not constitute an admission that the publication forms a part of
the common general knowledge in the art, in Australia or any other country.
In the claims which follow and in the preceding description of the invention,
except where the context requires otherwise due to express language or
necessary implication, the word “comprise” or variations such as “comprises” or
“comprising” is used in an inclusive sense, i.e. to specify the presence of the
stated features but not to preclude the presence or addition of further features in
various embodiments of the invention.
6249551_1 (GHMatters) P96993.NZ TERUNI
Claims (10)
1. A method of providing a portion of a transformer comprising: forming a core of the transformer by: providing transformer core material, cutting individual laminations, bending each individual lamination into generally C-shaped members, stacking a first plurality of bent C-shaped members to define a first core portion having a main leg and two opposing end legs, stacking a second plurality of bent C-shaped members to define a second core portion having a main leg and two opposing end legs, arranging the main legs of the first and second core portions in a back–to-back manner to define the core wherein a core leg is defined by the two main legs of the first and second core portion, and opposing core yokes are defined by the end legs of the first and second core portions, and winding conductive material directly around the core leg to form a primary winding and secondary winding in any order of arrangement, thus providing a first transformer portion.
2. The method of claim 1, wherein the step of providing transformer core material provides a sheet of ferromagnetic metal.
3. The method of claim 1 or claim 2, wherein, prior to the step of winding the low voltage winding, the method includes clamping the main legs to be in contacting, back-to-back relation.
4. The method of any one of claims 1 to 3, wherein during the step of winding the low voltage winding, cooling ducts are provided in the low voltage winding.
5. The method of any one of claims 1 to 4, wherein during the step of winding the high voltage winding, cooling ducts are provided in the high voltage winding. 6249551_1 (GHMatters) P96993.NZ TERUNI
6. The method of any one of claims 1 to 5, wherein the step of winding the conductive material to define the primary winding and the secondary winding includes winding the conductive material simultaneously with insulation material.
7. The method of any one of claims 1 to 6, further comprising: providing a pair of generally C-shaped side legs, coupling one side leg to the end legs of the first core portion, and coupling the other side leg to the end legs of the second core portion thereby defining in a single phase transformer.
8. The method of claim 7, wherein the coupling steps include engaging protrusions in the side legs with slits in the end legs and engaging protrusions in the end legs with slits in the side legs.
9. The method of any one of claims 1 to 8, further comprising: providing second and third transformer portions in the same manner as the first core portion, coupling end legs of the first core portion of the second transformer portion to the end legs of the second core portion of the first transformer portion, coupling end legs of the second core portion of the third transformer portion to the end legs of the first core portion of the first transformer portion, coupling a first C-shaped side leg to the end legs of the second core portion of the second transformer portion, and coupling a second C-shaped side leg to the end legs of the first core portion of the third transformer portion to define a three-phase transformer.
10. The method of claim 9, wherein the steps of coupling the end legs include engaging protrusions in the end legs of the first transformer portion with slits in the associated end legs of each of the second and third transformer portions and engaging protrusions in the end legs of each of the second and 6249551_1 (GHMatters) P96993.NZ TERUNI
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/295,199 US9601257B2 (en) | 2011-11-14 | 2011-11-14 | Wind-on core manufacturing method for split core configurations |
US13/295,199 | 2011-11-14 | ||
PCT/US2012/062035 WO2013074268A1 (en) | 2011-11-14 | 2012-10-26 | Wind-on core manufacturing method for split core configurations |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ624461A NZ624461A (en) | 2015-11-27 |
NZ624461B2 true NZ624461B2 (en) | 2016-03-01 |
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