WO2015180632A1

WO2015180632A1 - Light-weight alternating-current contactor iron core and manufacturing method therefor

Info

Publication number: WO2015180632A1
Application number: PCT/CN2015/079871
Authority: WO
Inventors: 刘津平; 刘昊; 李强; 高萌
Original assignee: 成都海沃斯电气技术有限公司
Priority date: 2014-05-30
Filing date: 2015-05-27
Publication date: 2015-12-03
Also published as: CN103985603A; CN103985603B

Abstract

A light-weight alternating-current contactor iron core. The iron core is formed by stacking silicon steel sheets, and a hollow structure (1) is arranged on each silicon steel sheet, so as to reduce the weight of the iron core. By conducting light-weight processing on the iron core, the weight of an alternating-current contactor device is reduced, thereby further improving the operating efficiency and reliability of an alternating-current contactor. The actual weight reduction effect can reach or even exceed 17%, and for a high-power contactor, the weight reduction effect is outstanding. By selecting a hollow position reasonably, the influence on the structural strength of the iron core can be reduced, and the influence of the hollow structure on the magnetic conductivity of the iron core can be compensated by adjusting parameters of a drive system, etc., so that the normal use of the iron core may not be affected. The alternating-current contactor iron core is suitable to be used in space equipment, aerospace equipment, naval ships, vehicles, etc.

Description

Lightweight AC contactor core and manufacturing method thereof

Technical field

The present invention relates to the field of AC contactor technology, and in particular to a lightweight AC contactor core structure and a method of manufacturing such an iron core.

Background technique

AC contactor is a kind of low-voltage electrical appliance with a wide range of applications. It is based on the working principle of “energized, live, and power-off”. When using AC control power, the hysteresis loss and eddy current loss in the core and short-circuit ring account for More than 90% of the total energy consumption increases the power loss on the grid line and shortens the service life of the contactor coil. In order to change this high energy consumption operation, China has promulgated GB 21518-2008 "AC contactor energy efficiency limit value and energy efficiency rating", which specifies the energy efficiency rating, energy efficiency limit value, energy conservation evaluation value and test method of AC contactor. It has played a positive role in the research on energy saving and electronic control technology of AC contactors.

At present, the energy-saving technology of AC contactor has been greatly developed with the wide application of electronic control technology. By changing the AC operation mode of the excitation coil of the AC contactor, the DC operation is maintained, and the DC maintains the operation mode, so that the energy efficiency level of the AC contactor is constant. improve. The AC contactor is a mechatronic structure. The electronic control method of changing the AC contactor is far from optimizing the operating efficiency and manufacturing cost of the contactor. The weight of the AC contactor is a problem that needs to be solved, especially for aerospace, aerospace equipment and AC contactors on various ships, vehicles and other equipment. The weight of the product is a problem that cannot be ignored. In AC contactor devices (including iron cores, excitation coils, operating mechanisms, and control systems, etc.), the weight of the core usually exceeds 40% of the total weight. By reducing the weight of the core, the weight of the device can be greatly reduced. In particular, by reducing the weight of the moving iron core, it is possible to further reduce the suction power, increase the breaking speed, and reduce the running noise.

Summary of the invention

The object of the invention is to reduce the weight of the iron core, reduce the weight of the AC contactor device, and further improve the operating efficiency and reliability of the AC contactor.

The invention solves the technical problem, and adopts a technical solution, which is a lightweight AC contactor iron core, the iron core is composed of a silicon steel sheet stack, wherein the silicon steel sheet is provided with a hollow structure to reduce iron. Core weight.

The technical solution of the invention reduces the weight of the iron core by processing the hollow structure on the silicon steel sheet, and the actual weight reduction effect can reach or exceed 17%, especially for the high-power contactor, the weight reduction effect is very prominent. By reasonably selecting the hollow position, the influence on the strength of the core structure can be reduced, and the influence of the hollow structure on the magnetic permeability of the iron core can be compensated by adjusting the parameters of the drive system, etc., without affecting the normal use of the iron core.

Specifically, the hollow structure is a rectangular through hole or a circular through hole.

The hollow structure on the silicon steel sheet adopts rectangular through holes or circular through holes, which can be used in the production process of silicon steel sheets by stamping process. Once processed, it has the characteristics of mold structure and convenient processing. In particular, the rectangular through hole has the advantage of outstanding weight reduction effect.

Preferably, the hollow structure is disposed on a silicon steel sheet located in the middle of the iron core.

Since the magnetic lines of force are mainly concentrated near the surface of the iron core, the magnetic flux lines in the middle part of the iron core are relatively small, and the hollow steel sheets in the middle of the iron core are hollowed out, while the silicon steel sheets at both ends of the iron core are left untreated, which can be maximized. The effect of reducing the magnetic permeability of the core is reduced, and the holes formed by the hollow structure can be enclosed in the middle of the iron core without contact with the outside, which can reduce the chance of dirt leakage, reduce the corrosion rate of the iron core, and increase the iron. Core integrity and structural strength.

Preferably, the positions of the hollow structures on the adjacent silicon steel sheets do not coincide with each other.

The positions of the hollow structures on the adjacent silicon steel sheets do not coincide with each other, that is, the hollow structures on the adjacent silicon steel sheets are staggered. The iron core of this structure can greatly reduce the influence of the hollow structure on the strength of the core structure and reduce the influence on the magnetic permeability of the core.

Further, the iron core is a U-shaped iron core or an E-shaped iron core having a symmetrical structure.

U-shaped iron core and E-shaped iron core are the two most commonly used iron cores for AC contactors, especially E-type iron cores are commonly used in high-power AC contactors. Both the U-shaped core and the E-shaped core have symmetry, and the silicon steel sheet also has a corresponding symmetrical structure, which is very suitable for forming a core which does not overlap with each other on the adjacent silicon steel sheets, and can be realized by a simple process. structure.

It is recommended that the silicon steel sheets provided with the hollow structure in the iron core have the same structure, and the shape and size of the hollow structure at the same position on the silicon steel sheet are the same, and the adjacent silicon steel sheets are stacked and stacked.

In the technical solution, the hollow structure provided on the silicon steel sheet is the same, and the shape and size of the hollow structure at the same position on the silicon steel sheet are the same. For the movable iron core silicon steel sheet and the static iron core silicon steel sheet, the silicon steel sheet can be processed by the same pair of molds respectively, thereby reducing the production cost. When laminating, the adjacent silicon steel sheets are stacked on top of each other to realize the structural features of the hollow silicon steel sheets on the adjacent silicon steel sheets.

It is recommended that the hollow structures provided on the silicon steel sheets in the iron cores have the same position.

The scheme adopts two sets of silicon steel sheets with different structures. When stacked, the two sets of silicon steel sheets are stacked alternately, and the structural features of the hollowed-out structures on adjacent silicon steel sheets do not overlap each other.

Another object of the present invention is to provide a lightweight AC contactor core manufacturing method for U-shaped iron core or E-shaped core processing having a symmetrical structure, including hollowing and lamination processes, characterized in that Proceed as follows:

a processing a hollow structure at the same position on the silicon steel sheet, the hollow structure being located on both sides of the axis of symmetry of the silicon steel sheet;

b. When the laminations are stacked, the adjacent silicon steel sheets are stacked on top of each other, so that the positions of the hollow structures on the adjacent silicon steel sheets do not coincide with each other.

The iron core manufacturing method of the present scheme utilizes the symmetrical structure of the silicon steel sheet. For the static iron core and the moving iron core, the hollow mold is processed at the same position on the silicon steel sheet by the same auxiliary mold, and the adjacent silicon steel sheets are turned over by the laminated sheet. Release, reach adjacent silicon The positions of the hollow structures on the steel sheets do not coincide with each other. The feature of this scheme is that the machining of the hollow iron core and the moving iron core hollow structure respectively sample a pair of molds, which can reduce the processing cost. The scheme requires that the hollow structure is located on both sides of the axis of symmetry of the silicon steel sheet, so that the positions of the hollow structures on the adjacent silicon steel sheets are staggered.

The invention provides a lightweight AC contactor core manufacturing method for U-shaped iron core or E-shaped iron core processing having a symmetrical structure, comprising a hollowing and lamination process, wherein the specific steps are as follows:

α, the silicon steel sheets that need to be hollowed out are divided into two groups;

β, respectively, processing the hollow structure on the first group of silicon steel sheets and the second group of silicon steel sheets, and the positions of the hollow structures processed on the two sets of silicon steel sheets are different;

When the γ and lamination are stacked, the first group of silicon steel sheets and the second group of silicon steel sheets are alternately stacked, so that the positions of the hollow structures on the adjacent silicon steel sheets do not coincide with each other.

In the silicon steel sheet processing method, the static iron core and the moving iron core respectively require two pairs of molds to process two sets of silicon steel sheets, so that the positions of the hollowed-out structures processed on the two sets of silicon steel sheets are different, and the two sets of silicon steel sheets are stacked alternately when lamination. The positions of the hollow structures on the adjacent silicon steel sheets are not coincident with each other. The silicon steel sheet processing method is characterized in that the static iron core and the moving iron core respectively need two pairs of mold processing hollow structures, the position of the hollow structure is not limited, and the hollow structure on the symmetry axis can also realize the hollow structure on the adjacent silicon steel sheets. The arrangement of the positions of the silicon steel sheet is relatively simple, and the silicon steel sheet does not need to be turned over.

Preferably, the hollow structure is a rectangular through hole or a circular through hole.

The hollow structure adopts rectangular through hole or circular through hole, which can be processed once in the stamping process of silicon steel sheet. It has the characteristics of simple mold structure, convenient processing and high production efficiency, and the rectangular through hole also has the advantages of outstanding weight reduction effect.

The invention has the beneficial effects that the weight of the product can be significantly reduced on the basis of ensuring the basic performance of the AC contactor core. Due to the reduction of the weight of the moving iron core, the required suction force is reduced, the suction power can be reduced, and the energy saving effect can be achieved. Since the AC contactor is a large-volume low-voltage control appliance, the large- and medium-capacity AC contactors that are operating in the country are in millions of units, and the considerable energy can be saved every year by using the technology of the present invention. Moreover, the weight reduction of the moving iron core reduces the impact force of the suction, which is beneficial to reduce running noise, reduce wear and prolong the service life of the contactor.

DRAWINGS

1 is a schematic structural view of a movable iron core silicon steel sheet of Embodiment 1;

2 is a schematic structural view of a static iron core silicon steel sheet of Embodiment 1;

Figure 3 is a schematic view showing the assembly of the movable iron core of the first embodiment;

Figure 4 is a schematic view showing the assembly of the static iron core of the embodiment 1;

Figure 5 is a schematic view showing the structure of the movable iron core silicon steel sheet of the embodiment 2, wherein Fig. 5a is a front view of the moving iron core silicon steel sheet, and Fig. 5b is a front view of the moving iron core;

Figure 6 is a schematic view showing the structure of a static iron core silicon steel sheet of Embodiment 2, wherein Figure 6a is a front view of the static iron core silicon steel sheet, Fig. 6b The front view of the static iron core;

Figure 7 is a schematic view showing the structure of a U-shaped iron core iron core steel sheet;

Figure 8 is a schematic view showing the structure of a U-shaped iron core moving iron core silicon steel sheet.

In the figure, 1 is a rectangular through hole (hollow structure); 2 is a mounting hole; OP is an axis of symmetry.

detailed description

The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and embodiments.

The technical solution of the invention reduces the weight of the iron core by processing the hollow structure on the silicon steel sheet, and the actual weight reduction effect can reach more than 17%, especially for the high-power contactor, the weight reduction effect is more prominent. By reasonably selecting the hollow position, the influence on the strength of the core structure can be reduced, and the influence of the hollow structure on the magnetic permeability of the iron core can be compensated by adjusting the parameters of the drive system without affecting the normal use of the iron core. The energy-saving effect brought by the weight reduction of the moving iron core is not to be underestimated for the large-sized AC contactor.

Example 1

The iron core of this example is an E-shaped iron core, and the moving iron core and the static iron core are all composed of silicon steel sheets stacked, the moving iron core silicon steel sheet structure is shown in Fig. 1, and the static iron core silicon steel sheet structure is shown in Fig. 2, OP It is the axis of symmetry of silicon steel sheet. The circular through hole 2 in the figure is an assembly hole of the iron core, and includes a rivet hole for staking the iron core and a bracket hole for mounting the bracket. The rectangular through hole 1 in the figure is a hollow structure for weight reduction processing. Obviously, the hollow structure 1 can also be processed into a circular through hole. Although the weight reduction effect of the circular through hole is not as good as the rectangular through hole, the circular through hole is more convenient to process and the mold structure is simpler.

Figure 3 and Figure 4 respectively show the assembly diagram of the moving iron core and the static iron core of the present example. It can be seen that the hollowed out structure is processed on a silicon steel sheet located at the center of the iron core on the silicon steel sheet located at the two ends of the iron core. The hollow structure is not processed, but the original structure of the silicon steel sheet is maintained. In the movable iron core and the static iron core of this example, each silicon steel sheet provided with a hollow structure has the same structure, and the shape and size of the hollow structure at the same position on each silicon steel sheet are the same. When the silicon steel sheet of this structure is assembled, the hollowed-out positions of the entire core are coincident. Except that the silicon steel sheets at both ends of the iron core have no processing hollow structure, the hollowing can also be regarded as the hollowing out of the entire iron core. The iron core weight reduction effect of this structure is outstanding, but the influence on the core structure strength and magnetic permeability is relatively large.

Example 2

The iron core of this example is also an E-shaped iron core with a symmetrical structure. The structure of the moving iron core silicon steel sheet is shown in Fig. 5, and the structure of the static iron core silicon steel sheet is shown in Fig. 6. If one side of the silicon steel sheet is defined as the front side (A side), the reverse side is the back side (B side). 5 and FIG. 6, wherein FIG. 5a is a front view of the A-side of the moving iron core silicon steel sheet, FIG. 5b is a front view of the B-side of the moving iron core silicon steel sheet, and FIG. 6a is a front view of the A-side of the static iron core silicon steel sheet, and FIG. 6b is a front view of FIG. Main view of B side of static iron core silicon steel sheet. It can be seen that in this example, the hollow structure on the silicon steel sheet is located on both sides of the axis of symmetry of the silicon steel sheet, and the positions of the hollow structures on the adjacent silicon steel sheets do not coincide with each other when laminating. Figures 5a and 5b can also be seen as two different types of moving iron core silicon steel sheets, correspondingly, Figure 6a and Figure 6b It can also be seen as two types of static iron core silicon steel sheets with different structures.

According to the symmetry of the core (symmetry of the silicon steel sheet), the core of this example can be manufactured by two processing methods. The processing method can be explained by 5 and FIG. 6, taking the moving iron core as an example, see FIG. 5a and FIG. 5b.

The first processing method is that the silicon steel sheets which need to be hollowed out are processed into a hollow structure according to the shape shown in Fig. 5a, and each silicon steel sheet has the same structure, and the shape and size of the hollow structure at the same position on the silicon steel sheet are the same. When the sheets are stacked, the adjacent silicon steel sheets are stacked on each other so that the positions of the hollow structures on the adjacent silicon steel sheets do not coincide with each other. It can be seen from Fig. 5a and Fig. 5b that the silicon steel sheet processed according to the shape shown in Fig. 5a has a shape as shown in Fig. 5b, and the positions of the hollow structures in the two figures are just staggered and do not coincide with each other. The advantage of this processing method is that only one pair of molds can be used for the processing, and the structural features of the hollowed-out structures on the adjacent silicon steel sheets are not coincident by the stacking of the laminations. This processing method requires a position of the hollow structure, and the position of the hollow structure needs to be arranged on both sides of the axis of symmetry of the silicon steel sheet.

The second processing method is to divide the silicon steel sheets that need to be hollowed into two groups, the first group of silicon steel sheets are processed into a hollow structure according to the shape described in FIG. 5a, and the second group of silicon steel sheets are processed into a hollow structure according to the shape shown in FIG. 5b, two sets of silicon steel. The hollowed-out structures processed on the sheet are positioned differently and staggered. When the lamination is carried out, the first group of silicon steel sheets and the second group of silicon steel sheets are alternately stacked, the positions of the hollow structures on the silicon steel sheets are the same, and the positions of the hollow structures on the adjacent silicon steel sheets do not coincide with each other. This processing method is characterized by the need for two sets of molds for processing, and the lamination does not require a flipping operation. The processing method can set the hollow structure on the axis of symmetry of the silicon steel sheet, and realize the scheme of staggering the hollow structure on the symmetry axis of the adjacent silicon steel sheet.

For the processing method of the static iron core, it can be realized by referring to FIG. 6a and FIG. 6b and the above description, and details are not described herein again.

The iron core obtained by the above two processing methods has different structures of adjacent silicon steel sheets, and the structure of the interphase silicon steel sheets is the same, and the through holes formed by the hollow structure are not obtained in the obtained iron core, and the influence on the strength of the iron core structure is relatively small, and the core magnetic field is relatively small. The effect of the conductivity can also be reduced, but the weight loss effect is less.

For the U-shaped iron core with symmetrical structure, the structure of the static iron core silicon steel sheet and the moving iron core silicon steel sheet are as shown in Fig. 7 and Fig. 8, and the same method as above can be used for the hollowing processing to achieve the effect of weight reduction and energy saving. The structure and processing method of the present invention will not be described in detail.

180A specification contactor core weight comparison:

普通动铁芯硅钢片重量(g)Ordinary moving iron core silicon steel sheet weight (g)	镂空结构动铁心硅钢片重量(g)Hollow structure moving iron core silicon steel sheet weight (g)	降低重量比Reduce weight ratio
		降低重量比Reduce weight ratio	467467	378378	19％19%
普通静铁心硅钢片重量(g)Ordinary static core silicon steel sheet weight (g)	镂空结构静铁心硅钢片重量(g)Hollow structure static iron core silicon steel sheet weight (g)	降低重量比Reduce weight ratio	467467	378378	19％19%
		降低重量比Reduce weight ratio	935935	779779	17％17%

Claims

A lightweight AC contactor core, the core is composed of a stack of silicon steel sheets, characterized in that the silicon steel sheet is provided with a hollow structure to reduce the weight of the core, and the iron core is a U-shaped structure having a symmetrical structure Iron core or E-shaped iron core, wherein the silicon steel sheet with the hollow structure in the iron core has the same structure, and the shape and size of the hollow structure at the same position on the silicon steel sheet are the same, the adjacent silicon steel sheets are turned over, and the adjacent silicon steel sheets are hollowed out. The structural positions do not coincide with each other.
The lightweight AC contactor core according to claim 1, wherein the hollow structure is a rectangular through hole or a circular through hole.
A lightweight AC contactor core according to claim 1, wherein said hollow structure is disposed on a silicon steel sheet located in the middle of the core.
A lightweight AC contactor core according to claim 1, wherein the hollowed-out structure provided on the silicon steel sheets in the core is the same.
A lightweight AC contactor core manufacturing method for U-shaped core or E-shaped core processing having a symmetrical structure, including hollowing and lamination processes, characterized in that the specific steps are as follows:

a processing a hollow structure at the same position on the silicon steel sheet, the hollow structure being located on both sides of the axis of symmetry of the silicon steel sheet;

b. When the laminations are stacked, the adjacent silicon steel sheets are stacked on top of each other, so that the positions of the hollow structures on the adjacent silicon steel sheets do not coincide with each other.
A lightweight AC contactor core manufacturing method for U-shaped core or E-shaped core processing having a symmetrical structure, including hollowing and lamination processes, characterized in that the specific steps are as follows:

α, the silicon steel sheets that need to be hollowed out are divided into two groups;

β, respectively, processing the hollow structure on the first group of silicon steel sheets and the second group of silicon steel sheets, and the positions of the hollow structures processed on the two sets of silicon steel sheets are different;

When the γ and lamination are stacked, the first group of silicon steel sheets and the second group of silicon steel sheets are alternately stacked, so that the positions of the hollow structures on the adjacent silicon steel sheets do not coincide with each other.
The method of manufacturing a lightweight AC contactor core according to claim 5 or 6, wherein the hollow structure is a rectangular through hole or a circular through hole.