WO2015022904A1 - Fe基アモルファストランス磁心及びその製造方法、並びにトランス - Google Patents
Fe基アモルファストランス磁心及びその製造方法、並びにトランス Download PDFInfo
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- WO2015022904A1 WO2015022904A1 PCT/JP2014/070921 JP2014070921W WO2015022904A1 WO 2015022904 A1 WO2015022904 A1 WO 2015022904A1 JP 2014070921 W JP2014070921 W JP 2014070921W WO 2015022904 A1 WO2015022904 A1 WO 2015022904A1
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- 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
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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
- H01F1/15308—Amorphous metallic alloys, e.g. glassy metals based on Fe/Ni
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- 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
- H01F27/25—Magnetic cores made from strips or ribbons
Definitions
- the present invention relates to an Fe-based amorphous transformer magnetic core suitable for a step-up transformer for inverter output voltage mounted on a power conditioner, a manufacturing method thereof, and a transformer using the same.
- the generated DC power is converted from DC power to AC power of a desired frequency via an inverter, and further boosted to the voltage of the commercial power system by a step-up transformer, and then connected to the commercial power network. It is.
- power generation efficiency is improved by converting the generated AC power into DC power and further converting the DC power into AC power having a desired frequency via an inverter.
- Power conditioners used for solar power generation and wind power generation are designed in consideration of fluctuations in power generation within the year and fluctuations in daily power generation.
- the time during which the rated power generation amount is obtained is a part of the total operation time, and is often operated in an output band less than the rated output.
- the most power generation occurs in an output band (% with respect to the rated output) that is 30% to 70% of the rated output (for example, JP 2010-273489 A, JP 2012-2012 A). 120251).
- the transformer when the inverter is stopped, the transformer may be maintained in a magnetized state, which is a so-called residual magnetization state. In this case, magnetic saturation is easily reached when the operation is restarted, and normal operation cannot be performed.
- a control circuit in order to prevent magnetic saturation in the power conditioner, current and voltage input to the input side (primary side) of the step-up transformer and current output from the output side (secondary side and boost side) And a control circuit are arranged so that magnetic saturation does not occur.
- Japanese Patent Application Laid-Open Nos. 2010-273489 and 2012-120251 disclose power conditioners having a function of offset correction before the start of operation.
- the control circuit is not only complicated, but also has a problem in terms of versatility and simplicity because it is essential to design in accordance with the characteristics of each transformer core.
- Japanese Patent Application Laid-Open No. 2008-177517 discloses that annealing is performed without a magnetic field to increase the magnetic resistance and suppress magnetic saturation.
- Japanese Patent Application Laid-Open No. 2008-177517 also describes that annealing at a low temperature of 300 ° C. or lower increases the magnetic resistance and suppresses magnetic saturation.
- Adopting a technique such as annealing in a non-magnetic field or low-temperature annealing described in Japanese Patent Application Laid-Open No. 2008-177517 described above to impart a characteristic that is difficult to cause magnetic saturation to the transformer itself is not necessarily provided with a complicated control circuit. This is effective in that it is not necessary.
- FIG. 2 shows a BH loop (magnetic hysteresis curve showing a change in magnetic flux density (B) with respect to an external magnetic field (H)) of a transformer (transformer) using a conventionally proposed Fe-based amorphous alloy ribbon.
- BH loop magnetic hysteresis curve showing a change in magnetic flux density (B) with respect to an external magnetic field (H)
- H external magnetic field
- FIG. 2 shows a BH loop (magnetic hysteresis curve showing a change in magnetic flux density (B) with respect to an external magnetic field (H)) of a transformer (transformer) using a conventionally proposed Fe-based amorphous alloy ribbon.
- B magnetic flux density
- H external magnetic field
- the magnetic core of the transformer is likely to cause magnetic saturation. That is, it is likely to be in a state in which no more magnetic flux can pass through the magnetic body, in other words, in the same state as an air core magnetic core such as an air core coil. Then, the induced electromotive force generated by electromagnetic induction becomes very small, a large current (excitation inrush current) more than 10 times the rated current flows, and a phenomenon that makes normal boosting and operation difficult occurs.
- the magnetic permeability ( ⁇ ) in the operating range is as large as possible, and this is the same when the operation start point becomes Br due to DC bias.
- ⁇ the magnetic permeability ( ⁇ ) in the operating range
- the present invention has been made in view of the above.
- the present invention is an Fe-based amorphous transformer in which the magnetic saturation of the transformer core is suppressed without deteriorating the noise level, the occurrence of excessive excitation inrush current (large current) is prevented, and the core iron loss is reduced.
- a magnetic core, a manufacturing method thereof, and a transformer capable of stably restarting operation are provided.
- a Fe-based amorphous transformer core that is manufactured by laminating thin Fe-based amorphous alloy ribbons and satisfies the following (1) to (3) in a DC BH curve measured by applying a magnetic field of 80 A / m to the magnetic core. is there.
- B80 represents the magnetic flux density (T) when magnetized with a magnetic field of 80 A / m, and Br is magnetized with a magnetic field of 80 A / m, and then the magnetic field is reduced to 0 A / m.
- the Fe-based amorphous alloy ribbon alloy comprises 2 atomic% to 13 atomic% Si (silicon), 8 atomic% to 16 atomic% B (boron), and 3 atomic% or less C. (Carbon) and the balance is preferably an alloy of Fe (iron) and inevitable impurities.
- a transformer including the Fe-based amorphous transformer core according to ⁇ 1> and at least one pair of conductive wires wound around the Fe-based amorphous transformer core.
- ⁇ 3> The transformer described in ⁇ 2> is connected to the output side of the inverter.
- ⁇ 4> The method for producing an Fe-based amorphous transformer magnetic core according to ⁇ 1>, Cutting and laminating the Fe-based amorphous alloy ribbon to produce a laminate; Heat-treating the laminated body at a magnetic field of 0 A / m with a holding temperature exceeding 300 ° C. and not higher than 150 ° C. lower than the crystallization start temperature of the amorphous alloy, and holding time not shorter than 1 hour and not longer than 6 hours; , This is a method for manufacturing an Fe-based amorphous transformer magnetic core.
- the magnetic saturation of the transformer core is suppressed without deteriorating the noise level, the occurrence of excessive excitation inrush current (large current) is prevented, and the iron core loss is reduced.
- An amorphous transformer core and a method for manufacturing the same are provided.
- ADVANTAGE OF THE INVENTION According to this invention, the transformer which can be restarted stably is provided.
- the control circuit inside the power conditioner can be general-purpose and simple, and the power conditioner can be stably restarted. .
- FIG. 1 is a direct current BH curve showing an example of the relationship between the magnetic flux density (B) and the external magnetic field (H) of the Fe-based amorphous magnetic core produced in the example.
- FIG. 2 is a DC BH curve showing the relationship between the magnetic flux density (B) of the conventional magnetic core and the external magnetic field (H).
- FIG. 3 is a schematic cross-sectional view conceptually showing an embodiment of a production apparatus for producing an Fe-based amorphous alloy ribbon.
- FIG. 4 is a schematic perspective view showing an example of the Fe-based amorphous magnetic core of the present invention.
- Fe-based amorphous transformer core of the present invention a transformer including the magnetic core
- a transformer including the magnetic core hereinafter also referred to as “Fe-based amorphous transformer”.
- the Fe-based amorphous transformer magnetic core of the present invention is a magnetic core produced by laminating Fe-based amorphous alloy ribbons.
- the unit of B80 and Br is T (Tesla).
- B80 represents the magnetic flux density (T) when magnetized with a magnetic field of 80 A / m
- Br is magnetized with a magnetic field of 80 A / m and then the magnetic field is 0 (zero). It represents the residual magnetic flux density (T) when changed to A / m.
- the transformer is a transformer or a transformer formed by winding at least one pair of conductive wires around a magnetic core.
- a device having a magnetic core and two or more windings and which does not change position relative to each other receives alternating current power from one or more circuits, and induces electromagnetic induction. This means that voltage and current are transformed by action to supply AC power of the same frequency to one or more other circuits.
- the magnetic core produced by laminating the Fe-based amorphous alloy ribbon is not particularly limited as long as it has a laminated form.
- a so-called laminated magnetic core in which thin ribbons formed into a predetermined shape are laminated, a so-called wound magnetic core in which thin ribbons are wound, and the like are included.
- the wound core is advantageous because it can easily form a laminated form for an extremely thin amorphous alloy ribbon.
- the present invention conducted an evaluation study on magnetic properties that can be imparted by heat treatment to a laminate in which Fe-based amorphous alloy ribbons are laminated.
- the present inventors have found that magnetic characteristics that enable both iron loss reduction and noise suppression can be provided.
- a smaller current permeability ⁇ causes a larger current to flow through the primary winding. Accordingly, it is preferable that the magnetic permeability ( ⁇ ) is large, and it is desirable that the value obtained by subtracting the residual magnetic flux density from the magnetic flux density (B-Br) is large. From the viewpoint of avoiding the occurrence of magnetic saturation during operation, it is desirable that Br is low.
- B80 and Br satisfy all of the above (1) to (3). By doing so, magnetic saturation of the magnetic core is suppressed, and generation of an excessive inrush current is prevented. In addition, iron loss can be reduced and noise can be suppressed.
- the evaluation was performed up to B80 because it is a range during normal operation in which iron loss is regarded as important.
- the magnetic flux density (B80) when magnetized with a magnetic field of 80 A / m is 1.1 T or more.
- a large absolute value of B80 is considered to be an indispensable characteristic for the magnetic core to operate without magnetic saturation in normal operation. The larger the value of B80, the better.
- B80 is less than 1.1 T, the difference from the residual magnetic flux density (Br) becomes small, and magnetic saturation is likely to occur.
- B80 is more preferably 1.2T or more for the same reason as described above.
- B80 can obtain a higher value by raising the heat treatment temperature or performing a specific heat treatment in a magnetic field.
- the upper limit of B80 is substantially about 1.4T.
- the residual magnetic flux density Br when the magnetic field is changed to 0 A / m is 0.5 T or more and 0.7 T or less.
- Br exceeds 0.7T, an attempt to obtain a fluctuation width corresponding to the design magnetic flux density from the demagnetized state causes the magnetic core to be magnetically saturated and an excessive inrush current flows.
- Br be as low as possible.
- Br is preferably 0.6 T or more and 0.7 T or less for the same reason as described above.
- the difference obtained by subtracting Br from B80 (B80 ⁇ Br) is set to 0.6T or more.
- B80-Br is preferably 0.65 T or more for the same reason as described above.
- the upper limit value of B80-Br is not particularly limited, but in reality, the upper limit is about 0.8T.
- the Fe-based amorphous transformer magnetic core of the present invention may be produced by any method without any limitation as long as it can obtain a magnetic core satisfying the above (1) to (3).
- A Laminating a Fe-based amorphous alloy ribbon (ribbon) to produce a laminate
- B Crystallizing an amorphous alloy with a magnetic field of 0 A / m and a holding temperature exceeding 300 ° C. A process of heat-treating at a temperature lower than the start temperature by 150 ° C. or lower and holding time from 1 hour to 6 hours.
- a desired number of strip-shaped ribbons molded into a predetermined shape may be stacked to form a laminate, or a so-called laminated magnetic core, or a long ribbon (ribbon) ) May be wound around a desired magnetic core to form a wound core.
- the laminate manufactured in the step (A) is heat-treated in an environment without a magnetic field.
- Heat treatment without a magnetic field (0 A / m) is particularly suitable for dramatically reducing the residual magnetic flux density (Br).
- the holding temperature to be held at the time of the heat treatment is set to a range not lower than 300 ° C. and not more than 150 ° C. lower than the crystallization start temperature of the amorphous alloy. If the holding temperature is 300 ° C. or lower, B80 becomes too small, and consequently the value of B80-Br becomes too small to prevent magnetic saturation of the magnetic core, and the value of Br becomes too low, resulting in noise. Will become bigger. Furthermore, since the distortion
- the holding temperature is preferably higher than 300 ° C. and not higher than 340 ° C., more preferably not lower than 310 ° C. and not higher than 330 ° C., for the same reason as described above.
- the crystallization start temperature of the amorphous alloy is measured as the heat generation start temperature when the temperature of the Fe-based amorphous alloy ribbon is increased from room temperature to 20 ° C./min with a differential scanning calorimeter (DSC). Is.
- the holding time for holding at the holding temperature during the heat treatment is in the range of 1 hour to 6 hours.
- the holding time is less than 1 hour, performance variation for each magnetic core increases. Further, the variation is such that B80 becomes too small, and consequently the value of B80-Br becomes too small, so that magnetic saturation of the magnetic core cannot be prevented, and the value of Br becomes too low and noise increases. Magnify in the direction.
- the holding time exceeds 6 hours, it is difficult to maintain the amorphous state of the alloy, and Br becomes too large, so that magnetic saturation of the magnetic core tends to occur.
- the holding time is preferably 1 hour or more and 6 hours or less for the same reason as described above.
- desired values of Br and B80 can be obtained by performing the heat treatment in a magnetic field and in an appropriate holding temperature environment. Further, since the heat capacity changes as the size of the magnetic core changes, it is desirable to optimize the holding temperature and holding time each time.
- the Fe-based amorphous transformer of the present invention can be manufactured as a transformer having primary and secondary input / output terminals by winding a pair of conductive wires around the magnetic core manufactured by the above process. Since the Fe-based amorphous transformer of the present invention can prevent magnetic saturation, it is suitable for connection to the output side of the inverter.
- the transformer of the present invention can be applied as a step-up transformer, an insulating transformer, and a step-down transformer.
- the transformer of the present invention is particularly suitable for a step-up transformer.
- the Fe-based amorphous alloy ribbon alloy that forms the Fe-based amorphous magnetic core of the present invention is preferably an Fe-Si-B-based alloy or an Fe-Si-BC-based alloy.
- the Fe—Si—B based amorphous alloy contains 2 atomic% to 13 atomic% of Si and 8 atomic% to 16 atomic% of B, with the balance being substantially Fe and inevitable impurities.
- the alloy is preferred.
- the Fe-Si-BC amorphous alloy contains 2 atomic% to 13 atomic% Si, 8 atomic% to 16 atomic% B, and 3 atomic% or less C, with the balance being Fe. Further, an alloy of a system having a composition that is an inevitable impurity is preferable.
- the case where Si is 10 atomic% or less and B is 17 atomic% or less is preferable in terms of high saturation magnetic flux density Bs.
- the amount of C is preferably 0.5 atomic% or less.
- the thickness of the Fe-based amorphous alloy ribbon is preferably in the range of 15 ⁇ m to 40 ⁇ m, and more preferably in the range of 20 ⁇ m to 30 ⁇ m.
- the thickness is 15 ⁇ m or more, it is advantageous in that the mechanical strength of the ribbon can be maintained, the space factor is increased, and the number of layers when laminated is reduced.
- the thickness is 40 ⁇ m or less, it is advantageous in that the eddy current loss can be suppressed small, the bending strain when the laminated magnetic core is processed can be reduced, and the amorphous phase can be easily obtained stably.
- the length in the width direction (width length) perpendicular to the longitudinal direction of the Fe-based amorphous alloy ribbon is preferably 15 mm or more and 250 mm or less.
- the width is 15 mm or more, a large-capacity magnetic core is easily obtained.
- the width is 250 mm or less, an alloy ribbon having a high uniformity of plate thickness in the width direction can be easily obtained.
- the width is preferably 50 mm or more and 220 mm or less from the viewpoint of obtaining a practical magnetic core with a large capacity.
- the production of the Fe-based amorphous alloy ribbon can be performed by a known method such as a liquid quenching method (single roll method, twin roll method, centrifugal method, etc.).
- a liquid quenching method single roll method, twin roll method, centrifugal method, etc.
- the single roll method is a manufacturing method with relatively simple manufacturing equipment and capable of stable manufacturing, and has excellent industrial productivity.
- the shape of the magnetic core of the present invention is not limited to a circle but may be a rectangle as shown in FIG.
- the magnetic core of the present invention may be made from a plurality of Fe-based amorphous alloy ribbons. Furthermore, the magnetic core of the present invention may have an overlap or a back trap joint.
- Example 1 -Fabrication of Fe-based amorphous alloy ribbon-
- An alloy ribbon (alloy ribbon) was produced.
- the unit of the composition ratio is “atomic%”.
- an Fe-based amorphous alloy ribbon manufacturing apparatus similar to the apparatus 100 shown in FIG. 3 was prepared. Here, the following cooling rolls were used.
- a molten alloy composed of Fe, Si, B, C and unavoidable impurities (hereinafter also referred to as an Fe—Si—BC alloy melt) was prepared in a crucible. More specifically, an Fe-based amorphous alloy ribbon having the above composition is manufactured by melting a master alloy composed of Fe, Si, B, and inevitable impurities, adding carbon to the obtained molten metal, and mixing and dissolving the resultant alloy. An alloy melt was prepared.
- this Fe—Si—B—C-based alloy melt is rotated from the opening of a melt nozzle having a rectangular (slit shape) opening having a long side length of 25 mm and a short side length of 0.6 mm. It was discharged onto the surface of the cooling roll and rapidly solidified to produce 30 kg of an Fe-based amorphous alloy ribbon having a width of 170 mm and a thickness of 24 ⁇ m.
- Cooling roll ⁇ Material: Cu alloy ⁇ Diameter: 400 mm -Arithmetic mean roughness Ra of the cooling roll surface: 0.3 ⁇ m ⁇ Discharge pressure of molten alloy: 20kPa ⁇ Cooling roll peripheral speed: 25 m / s -Molten metal temperature: 1300 ° C ⁇ Distance between molten metal nozzle tip and cooling roll surface: 200 ⁇ m
- the saturation magnetic flux density (Bs) of the Fe-based amorphous alloy ribbon having the above composition was 1.63T.
- Bs uses a Fe-based amorphous alloy ribbon having a width of 10 mm and a length of 120 mm, and applying a DC magnetic field of 2400 A / m in the longitudinal direction of the ribbon while maintaining a heat treatment temperature of 320 ° C. and a holding time of 2 hours.
- each alloy ribbon has an overlap portion 2 after being cut into a predetermined size and laminated on a core material of a predetermined size. Was wound up to prepare a laminate.
- the magnetic core of the present invention Fe-based amorphous transformer magnetic core 1 shown in FIG. 4
- a comparative magnetic core were prepared by holding at 360 ° C. for 1 hour.
- the produced laminate was heat treated at 330 ° C. for 1 hour while applying a DC magnetic field of 12.5 A / m and 800 A / m in the longitudinal direction of the magnetic path, that is, in the circumferential direction of the magnetic core.
- the space factor (LF) of the magnetic core was 86%, and the effective cross-sectional area of the magnetic core was 73 cm 2 .
- the space factor LF of the magnetic core is the ratio of the cross-sectional area of the ribbon in the cross-sectional area of the laminate of ribbons, and the closer to 100%, the higher the percentage of the ribbon in the laminate.
- the space factor of the magnetic core was determined by measuring the mass M of the ribbon strip cut from the Fe-based amorphous alloy ribbon to a size of width W [mm] and length 2400 [mm]. The thickness t1 [mm] of the alloy ribbon was obtained, and LF was calculated by the following formula (b).
- t1 M / (W ⁇ 2400 ⁇ density of amorphous alloy [g / mm 3 ])
- LF 100 ⁇ number of thin ribbons ⁇ t1 / C
- the “density of the amorphous alloy” is a value obtained by a constant volume expansion method using helium gas.
- FIG. 1 shows a DC BH curve when the holding temperature during heating is 300 ° C. and 330 ° C. Based on the DC BH curve created in this way, the residual magnetic flux density Br (T) and the magnetic flux density B80 (T) when magnetized in a magnetic field of 80 A / m are obtained, and from these values, “B80 ⁇ Br ”Was determined. These results are shown in Tables 1 to 3 below.
- B80 can obtain 1.1 T or more at a holding temperature of 310 ° C. or more.
- Br is preferably as small as possible in terms of magnetic saturation, but considering the balance with B80 and noise shown in Table 1, Br is preferably in the range of 0.5T to 0.7T.
- B80-Br In order to prevent magnetic saturation, the larger the difference between B80-Br, that is, B80 and Br, the better. As shown in Table 3, even when Br shown in Table 2 is in the range of 0.5T to 0.7T, it can be seen that B80-Br can obtain a relatively high value of 0.6 or more. .
- a conductive wire is wound a predetermined number of times on a magnetic core heat-treated at 330 ° C. and without a magnetic field, and the primary side voltage: 200 V and the secondary side voltage: 6600 V are increased.
- a transformer was produced.
- a comparative step-up transformer having the same voltage was produced by similarly winding a conducting wire around a magnetic core heat-treated by applying a magnetic field of 330 ° C. and 800 A / m in the circumferential direction of the wound core. These are step-up transformers assuming the output side of the inverter.
- a rated voltage of 200 V is supplied to the primary winding with no load connected to these two transformers, and the inrush current flowing in the primary winding at that time is recorded with an oscilloscope.
- the peak value of the wave was measured.
- the current value was 25 A, which was less than the rated current (50 A) of the produced transformer.
- a maximum of 175 A was detected, and a current more than three times the rated current flowed through the primary winding. This is presumed to be a phenomenon caused by magnetic saturation.
- Example 2 A Fe-based amorphous alloy ribbon (alloy ribbon) was produced in the same manner as in Example 1 except that the composition of the Fe-based amorphous alloy ribbon was changed to the following composition in Example 1, and a magnetic core was further formed. Was made. And using the produced magnetic core, the wound magnetic core was obtained similarly to Example 1, and it evaluated by the method similar to Example 1 about each characteristic. The results are shown below. Composition: Fe 79.7 Si 9 B 11 C 0.3 (atomic%)
- B80 was able to obtain 1.1T or higher in the region where the holding temperature was 310 ° C. or higher as in Example 1.
- Br is preferably in the range of 0.5T to 0.7T, considering the balance with B80 shown in Table 5 above and the noise.
- the Br shown in Table 6 is in the range of 0.5T to 0.7T in the region where the holding temperature is 350 ° C. to 360 ° C.
- B80-Br was a relatively high value of 0.6 or more.
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Abstract
Description
太陽光発電では、発電された直流電力は、インバータを介して直流電力から所望とする周波数の交流電力に変換され、さらに昇圧トランスによって、商用電力系統の電圧に昇圧された後、商用電力網に繋がれる。また、風力発電においても、発電された交流電力を直流電力に変換し、さらにインバータを介して直流電力から所望とする周波数の交流電力に変換することで発電効率の向上が図られている。
従来、パワーコンディショナでの磁気飽和が起こるのを防ぐため、昇圧トランスの入力側(1次側)に入力される電流や電圧と、出力側(2次側、昇圧側)から出力される電流や電圧と、を検出し、磁気飽和が起こらないように制御回路が配されている。
例えば、制御回路の一例として、特開2010-273489号公報、特開2012-120251号公報には、運転開始前にオフセット補正する機能を備えるパワーコンディショナが開示されている。
しかしながら、制御回路は、複雑なだけでなく、各トランスの磁心ごとの特性に合わせた設計が不可欠なため、汎用性かつ簡便性の点で問題があった。
また、特開2008-177517号公報には、無磁場で焼鈍することで磁気抵抗が大きくなり、磁気飽和が抑制できることの開示がある。また、特開2008-177517号公報には、300℃以下の低温で焼鈍することで磁気抵抗が大きくなり、磁気飽和が抑制できることの記載もある。
図2は、従来から提案されているFe基アモルファス合金薄帯を用いたトランス(変圧器)のBHループ(外部磁場(H)に対する磁束密度(B)の変化を示す磁気ヒステリシス曲線)を示す。通常の運転時は、交流の周波数に合わせて交番磁場がかかり、この曲線上の値に相当する磁化がなされる。また、運転停止時には、停止時の磁場に応じて、いくらか磁化された状態で停止される。例えば、図2で、H=10A/m以上の状態で停止された場合は、H=0A/mでのBHループの磁束密度Bの正側の線上である約0.8T(テスラ)で磁化された状態となっている(H=0A/mでの磁束密度を「残留磁束密度(T)」といい、Brで表される。)。
したがって、動作範囲における透磁率(μ)は、できる限り値が大きいことが好ましく、これは直流偏磁によって動作開始点がBrになったときも同様である。換言すれば、磁束密度から残留磁束密度を減じた値(B-Br)は、大きいほど望ましいといえる。そして、運転中の磁気飽和の発生回避の観点のみから見れば、Brは低いほど望ましい。
<1> Fe基アモルファス合金薄帯を積層して作製され、磁心に80A/mの磁場を印加して測定した直流BH曲線において、下記(1)~(3)を満たすFe基アモルファストランス磁心である。
B80≧1.1T ・・・(1)
0.5T≦Br≦0.7T ・・・(2)
B80-Br≧0.6T ・・・(3)
前記(1)~(3)において、B80は、80A/mの磁場で磁化したときの磁束密度(T)を表し、Brは、80A/mの磁場で磁化した後、磁場を0A/mに変化させた場合の残留磁束密度(T)を表す。
上記<1>において、Fe基アモルファス合金薄帯の合金は、2原子%~13原子%のSi(ケイ素)と、8原子%~16原子%のB(ホウ素)と、3原子%以下のC(炭素)とを含み、残部がFe(鉄)及び不可避不純物である合金であることが好ましい。
Fe基アモルファス合金薄帯を切断、積層して積層体を作製する工程と、
前記積層体を、0A/mの磁場で、保持温度を300℃を超えてアモルファス合金の結晶化開始温度よりも150℃低い温度以下とし、保持時間を1時間以上6時間以下として熱処理する工程と、
を有する、Fe基アモルファストランス磁心の製造方法である。
本発明によれば、安定的に運転再開が行えるトランスが提供される。
例えば本発明の変圧器をパワーコンディショナに適用した場合、パワーコンディショナ内部の制御回路を汎用かつ簡便にすることが可能であるとともに、パワーコンディショナを安定的に運転再開させることが可能になる。
B80≧1.1T ・・・(1)
0.5T≦Br≦0.7T ・・・(2)
B80-Br≧0.6T ・・・(3)
上記(1)~(3)において、B80は、80A/mの磁場で磁化したときの磁束密度(T)を表し、Brは、80A/mの磁場で磁化した後、磁場を0(ゼロ)A/mに変化させた場合の残留磁束密度(T)を表す。
また、本発明において、Fe基アモルファス合金薄帯を積層して作製された磁心とは、積層形態を有するものであれば、その形態は問わない。例えば、所定形状に成形された薄帯が積層された、いわゆる積層磁心や、薄帯が巻き回わされた、いわゆる巻磁心等が含まれる。特に巻磁心は、極めて薄いアモルファス合金薄帯にとって容易に積層形態を形成できるため有利である。
前述の通り、所定の磁束密度を得る必要のあるトランスでは、透磁率μが小さいほど一次巻線に大きな電流が流れてしまうことになる。
したがって、透磁率(μ)は大きい方が好ましく、磁束密度から残留磁束密度を減じた値(B-Br)は、大きい方が望ましいのである。そして、運転中の磁気飽和の発生を回避する観点からは、Brは低い方が望ましい。しかしながら、Brが低くなると、磁心の磁化過程が磁化反転となり、騒音が増大しやすい。また、鉄損もこれらの磁気特性に大きく依存する。
上記から、本発明においては、B80及びBrが上記(1)~(3)の全てを満足する。このようにすることで、磁心の磁気飽和が抑制され、過大な突入電流の発生が防止される。加えて、鉄損の低減や騒音の抑制も可能になる。B80迄にて評価を行なったのは、鉄損が重要視される通常運転時の範囲だからである。
中でも、B80は、上記と同様の理由から、1.2T以上がより好ましい。なお、B80は、熱処理温度を高めたり、特定の磁場中熱処理を行なうことで、より高い値を得ることができる。しかしながら、この場合には残留磁束密度(Br)も高い値となってしまうため、B80は、実質的には1.4T程度が上限となる。
中でも、Brは、上記と同様の理由から、0.6T以上0.7T以下が好ましい。
中でも、B80-Brは、上記と同様の理由から、0.65T以上が好ましい。
また、B80-Brの上限値には、特に制限はないが、現実的には0.8T程度が上限となる。
(B)前記積層体を、0A/mの磁場で、保持温度を300℃を超えてアモルファス合金の結晶化開始温度よりも150℃低い温度以下とし、保持時間を1時間以上6時間以下として熱処理する工程
保持温度が300℃以下であると、B80が小さくなり過ぎ、ひいてはB80-Brの値が小さくなり過ぎて、磁心の磁気飽和を防ぐことができないばかりか、Brの値が低くなり過ぎて、騒音が大きくなってしまう。さらに、保持温度が300℃を超えていることで、磁心に内在する歪が十分に取り除かれるため、磁心毎の性能バラツキが抑制される。
また、保持温度が「アモルファス合金の結晶化開始温度よりも150℃低い温度」を超える範囲であると、合金のアモルファス状態を安定に維持できないばかりか、Brが大きくなり過ぎ、磁心の磁気飽和が生じやすくなる。
中でも、保持温度は、上記と同様の理由から、300℃を超えて340℃以下が好ましく、310℃以上330℃以下がより好ましい。
保持時間が1時間未満であると、磁心ごとの性能バラツキが大きくなる。また、そのバラツキは、B80が小さくなり過ぎ、ひいてはB80-Brの値が小さくなり過ぎるため、磁心の磁気飽和を防ぐことができないばかりか、Brの値も低くなり過ぎて騒音が大きくなってしまう方向に拡大する。また、保持時間が6時間を超えると、合金のアモルファス状態を維持することが困難となり、かつ Brが大きくなり過ぎ、磁心の磁気飽和が生じやすくなる。中でも、保持時間は、上記と同様の理由から、1時間以上6時間以下が好ましい。
本発明のFe基アモルファストランスは、磁気飽和の発生を防止できるため、インバータの出力側に接続するものとして好適である。本発明のトランスとしては、昇圧トランス、絶縁トランス、降圧トランスとして適用することができる。本発明のトランスは、特に昇圧トランスに好適である。
前記Fe-Si-B系アモルファス合金としては、2原子%~13原子%のSi及び8原子%~16原子%のBを含有し、残部が実質的にFe及び不可避不純物である組成を有する系の合金が好ましい。
また、前記Fe-Si-B-C系アモルファス合金としては、2原子%~13原子%のSi、8原子%~16原子%のB、及び3原子%以下のCを含有し、残部がFe及び不可避不純物である組成を有する系の合金が好ましい。
いずれの系においても、Siが10原子%以下であり且つBが17原子%以下である場合が、飽和磁束密度Bsが高い点で好ましい。また、Fe-Si-B-C系アモルファス合金薄帯では、Cを多く加え過ぎると、経年変化が大きくなるため、Cの量は0.5原子%以下が好ましい。
中でも、幅長は、大容量で実用的な磁心を得る観点から、50mm以上220mm以下がより好ましい。
-Fe基アモルファス合金薄帯の作製-
大気中での単ロール法によって、以下に示す方法で170mm幅、24μm厚の長尺状の、組成:Fe81.7Si2B16C0.3(原子%)で表されるFe基アモルファス合金薄帯(合金リボン)を作製した。組成比の単位は「原子%」である。
まず、坩堝内でFe、Si、B、C、及び不可避不純物からなる合金溶湯(以下、Fe-Si-B-C系合金溶湯ともいう。)を調製した。詳細には、Fe、Si、B、及び不可避不純物からなる母合金を溶解し、得られた溶湯に炭素を添加して混合し溶解させることで、上記組成のFe基アモルファス合金薄帯を製造するための合金溶湯を調製した。次いで、このFe-Si-B-C系合金溶湯を、長辺の長さ25mm×短辺の長さ0.6mmの矩形(スリット形状)の開口部を有する溶湯ノズルの開口部から、回転する冷却ロール表面に吐出し、急冷凝固させて幅:170mm、厚さ:24μmのFe基アモルファス合金薄帯30kgを作製した。
<Fe基アモルファス合金薄帯の作製条件>
・冷却ロール:・材質:Cu合金
・直径:400mm
・冷却ロール表面の算術平均粗さRa:0.3μm
・合金溶湯の吐出圧力:20kPa
・冷却ロールの周速:25m/s
・合金溶湯温度:1300℃
・溶湯ノズル先端と冷却ロール表面との距離:200μm
上記組成のFe基アモルファス合金薄帯の飽和磁束密度(Bs)は、1.63Tであった。Bsは、幅10mm、長さ120mmのFe基アモルファス合金薄帯を用い、その薄帯長手方向に2400A/mの直流磁界を印加しながら、熱処理温度:320℃、保持時間:2時間の条件にて熱処理を施した薄帯に対し、8000A/mの磁場を印加して測定した直流BH曲線の磁束密度の最大値(B8000)として求めた。
また、示差走査熱量計(DSC)によって求めた結晶化開始温度は、490℃であった。
上記で作製したFe基アモルファス合金薄帯を用い、図4に示すように、所定サイズの芯材に対して、所定サイズに切断、積層後、各合金薄帯を、オーバーラップ部分2を有するように巻き上げて、積層体を作製した。
また、上記とは別に、作製した積層体を、磁路長手方向、すなわち磁心の円周方向に12.5A/m、800A/mの直流磁界を印加しながら、330℃で1時間の熱処理を施し、比較用の磁心を作製した。
磁心の占積率は、Fe基アモルファス合金薄帯から幅W[mm]、長さ2400[mm]のサイズに切り出した薄帯片の質量Mを測定し、下記式(a)からFe基アモルファス合金薄帯の厚みt1[mm]を求め、下記式(b)によりLFを算出した。
t1=M/(W×2400×アモルファス合金の密度[g/mm3])・・・(a)
LF=100×薄帯の積層数×t1/C ・・・(b)
なお、上記の「アモルファス合金の密度」は、ヘリウムガスを用いた定容積膨張法により求められる値である。
また、磁心の実効断面積は、「実効断面積=C×D×LF」により算出した。
熱処理を施した磁心に、一次巻線30ターン、二次巻線5ターンを巻回し、直流磁化特性試験装置で、最大磁場80A/mで直流BH曲線を測定した。加熱時の保持温度を300℃、330℃とした場合の直流BH曲線を図1に示す。このように作成した直流BH曲線をもとに、残留磁束密度Br(T)、及び80A/mの磁場で磁化したときの磁束密度B80(T)を求め、さらにこれらの値から「B80-Br」の値を求めた。これらの結果を下記表1~表3に示す。
上記のように各磁心に一次巻線と二次巻線とを巻いた巻磁心の各々について、周波数60Hzで励磁磁束密度を1.3Tとして鉄損(W/kg)を測定した。測定結果を下記表4に示す。
本発明の巻磁心のうち、330℃、無磁場で熱処理した磁心に対して、導線を所定の回数巻回し、1次側の電圧:200V、2次側の電圧:6600Vとした本発明の昇圧トランスを作製した。また、比較として、330℃、800A/mの磁界を巻磁心の円周方向に印加して熱処理した磁心に対して同様に導線を巻回し、同電圧とした比較用の昇圧トランスを作製した。これらは、インバータの出力側を想定した昇圧トランスである。
これら2つのトランスに対して、負荷をつながない状態で、1次巻線に定格電圧200Vを供給し、そのときに1次巻線に流れる突入電流をオシロスコープで記録し、その突入電流の第3波の波高値を測定した。結果、本発明のトランスでは、電流値が25Aであり、作製したトランスの定格電流(50A)以下であった。他方、比較用のトランスでは、最大175Aを検出し、定格電流の3倍以上の電流が1次巻線に流れた。これは、磁気飽和により生じた現象と推測される。
実施例1において、Fe基アモルファス合金薄帯の組成を、以下に示す組成に変更したこと以外は、実施例1と同様にして、Fe基アモルファス合金薄帯(合金リボン)を作製し、さらに磁心を作製した。そして、作製した磁心を用いて、実施例1と同様に巻磁心を得て、各特性について実施例1と同様の方法で評価した。結果を以下に示す。
組成:Fe79.7Si9B11C0.3(原子%)
本明細書に記載された全ての文献、特許出願、および技術規格は、個々の文献、特許出願、および技術規格が参照により取り込まれることが具体的かつ個々に記された場合と同程度に、本明細書中に参照により取り込まれる。
Claims (5)
- Fe基アモルファス合金薄帯を積層して作製され、磁心に80A/mの磁場を印加して測定した直流BH曲線において、下記(1)~(3)を満たすFe基アモルファストランス磁心。
B80≧1.1T ・・・(1)
0.5T≦Br≦0.7T ・・・(2)
B80-Br≧0.6T ・・・(3)
〔B80は、80A/mの磁場で磁化したときの磁束密度(T)を表し、Brは、80A/mの磁場で磁化した後、磁場を0A/mに変化させた場合の残留磁束密度(T)を表す。〕 - 前記Fe基アモルファス合金薄帯の合金は、2原子%~13原子%のSiと、8原子%~16原子%のBと、3原子%以下のCとを含み、残部がFe及び不可避不純物である合金である請求項1に記載のFe基アモルファストランス磁心。
- 請求項1又は請求項2に記載のFe基アモルファストランス磁心と、前記Fe基アモルファストランス磁心に巻回された少なくとも1対の導線と、を備えたトランス。
- インバータの出力側に接続される、請求項3に記載のトランス。
- 請求項1又は請求項2に記載のFe基アモルファストランス磁心の製造方法であって、
Fe基アモルファス合金薄帯を積層して積層体を作製する工程と、
前記積層体を、0A/mの磁場で、保持温度を300℃を超えてアモルファス合金の結晶化開始温度よりも150℃低い温度以下とし、保持時間を1時間以上6時間以下として熱処理する工程と、
を有する、Fe基アモルファストランス磁心の製造方法。
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CN105580095B (zh) | 2017-07-18 |
DE112014003755T5 (de) | 2016-05-12 |
US20160203902A1 (en) | 2016-07-14 |
JPWO2015022904A1 (ja) | 2017-03-02 |
US9881735B2 (en) | 2018-01-30 |
CN105580095A (zh) | 2016-05-11 |
JP6402107B2 (ja) | 2018-10-10 |
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