CN101800127B - Method for manufacturing wound iron core and iron core manufactured by implementing method - Google Patents

Abstract

The invention discloses a method for preparing a wound iron core, which comprises a strip-shaped non-oriented magnetic material and comprises the following steps: 1) preparing mixed insulating paint; 2) feeding; 3) feeding; 4) setting parameters; 5) production; the method provided by the invention has few working procedures and simple preparation, greatly reduces the production cost, ensures the precision and consistency of the product, greatly improves the interlayer insulation performance, high temperature resistance, magnetic conduction effect and qualification rate of the iron core, adopts a constant-pressure gas and high oil pressure mode, combines 360-degree uniform pressing and winding of the non-oriented magnetic material, and simultaneously is matched with the mixed insulating coating to be uniformly coated on the surface of the non-oriented magnetic material so as to fully fill micro gaps generated due to material deformation and permeate into the material, thereby integrally improving the performance of the product; the iron core provided by the invention has the advantages of reasonable structure, high temperature resistance, high interlayer insulation performance and higher magnetic conduction effect.

Description

Winding iron core preparation method and iron core made by implementing the method

technical field

The invention relates to an iron core processing technology, in particular to a method for preparing a wound iron core and an iron core made by implementing the method.

Background technique

In the prior art, there are mainly two manufacturing methods for iron cores used in electrical appliances such as ballasts: lamination and winding.

The laminated iron core is made of non-oriented magnetic materials stacked in a certain shape. Because the non-oriented magnetic material sheets are not compact enough, there is an air gap in the magnetic circuit, and the high magnetic permeability direction of the local material is in line with the The direction of the magnetic circuit is inconsistent, so that the performance of the iron core is poor, and the electrical appliances made have high no-load loss and high noise.

In order to overcome the defects of the above-mentioned laminated cores, wound cores are usually used; in order to further improve performance and reduce magnetic flux leakage and energy loss, wound cores are generally made of non-oriented magnetic materials of a certain shape that are continuously wound. ; The existing non-oriented magnetic materials in ferrous metals are usually low-carbon, silicon-containing or non-silicon-containing iron or iron alloy materials and products, such as silicon steel sheets. It is coated with an insulating coating when it is stamped or rolled out by a machine. After it is formed, it must be annealed to remove residual stress and increase magnetic permeability. The annealing conditions vary according to different materials. Generally, annealing in an oxygen-free environment is required to prevent high-temperature oxidation, and the temperature is raised slowly to make the annealing temperature reach about 800°C. The annealing time takes about 6 to 10 hours. However, in the prior art, because the insulating paint applied by the magnetic ferroalloy material cannot withstand high temperature, the metal lattice texture cannot be effectively restored, that is, its reduction performance cannot reach the best state; and the current production volume The process of winding the iron core is complicated, there are many quality risks, and it is easy to cause a large number of defective products, and the production process requires a lot of manpower. At the same time, the price of silicon-containing materials is expensive, which greatly increases the production cost.

Contents of the invention

In view of the deficiencies of the above-mentioned iron cores in the prior art, one of the purposes of the present invention is to provide a winding iron core preparation method that requires few processes and can be completed by a single operation, while ensuring product quality;

The purpose of the present invention is also to provide an iron core with simple structure, high temperature resistance, no loss of interlayer insulation performance, and enhanced magnetic permeability of the material.

The technical scheme that the present invention adopts for realizing the above object is:

A method for preparing a wound iron core, comprising a strip of non-oriented magnetic material, comprising the following steps:

(1) Preparation of mixed insulating paint: used to evenly coat the surface of the non-oriented magnetic material, so as to fully fill into the tiny gaps produced by the deformation of the non-oriented magnetic material, and penetrate into the interior of the non-oriented magnetic material , and siliconize non-oriented magnetic materials during high temperature treatment;

(2) Feeding: Place a non-oriented magnetic material on the automatic feeder, and fix it tightly for feeding;

(3) Feeding: Pull the beginning part of the above-mentioned non-oriented magnetic material to the automatic winding machine, and position it for production;

(4) Setting parameters: According to the specifications of the iron core to be produced, the relevant required parameters are sequentially debugged and set on the automatic feeding machine and the automatic winding machine in advance;

(5) Production: Turn on the automatic feeding machine and automatic winding machine, and the automatic feeding machine will deliver the non-oriented magnetic material to the automatic winding machine at an even speed. The automatic winding machine uses constant pressure gas and high oil pressure combined with 360-degree uniform pressing and winding of the non-oriented magnetic material to form a cylindrical body;

The above steps (1) to (4) are in no order.

Described step (1), it specifically comprises the following steps:

(11) Preparation raw materials:

Prepare material A: prepare silicon oxide with a particle size of 1800-2200 mesh;

Prepare material B: prepare aluminum dihydrogen phosphate with a particle size of 1800-2200 mesh;

Preparation of material C: preparation of industrial alcohol;

(12) Stirring of ingredients: The weight percentages of the above-mentioned material A, material B and material C are 28-34% of material A, 28-34% of material B and 38-42% of material C to form a mixed insulating coating, and Stir the mixed insulating coating at room temperature;

(13) Mixing for later use: After uniformly mixing the above mixed insulating coatings, store them at 28-35°C for later use.

Described step (4), it specifically comprises the following steps:

(41) Open the automatic control mode of the automatic feeding machine and the automatic winding machine, and enter the setting mode of each relevant parameter;

(42) Correspondingly set the feeding length, drag piece delay, pressing position, welding position, pushing time, welding time, welding delay, pushing iron core, Coil material thickness, number of winding turns, product outer diameter and product inner diameter parameters, among which the relationship formula of coil thickness h, number of winding turns n, iron core outer diameter D, iron core inner diameter d and iron core space factor η as follows:

$\frac{\mathrm{<span\; class="notranslate">\; no</span>}}{<span\; class="notranslate">\; (</span>\mathrm{<span\; class="notranslate">\; D.</span>}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; d</span>}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; \&divide;</span>\mathrm{<span\; class="notranslate">\; 2</span>}<span\; class="notranslate">\; \&divide;</span>\mathrm{<span\; class="notranslate">\; h</span>}}<span\; class="notranslate">\; \&times;</span>\mathrm{<span\; class="notranslate">\; 100</span>}<span\; class="notranslate">\; \%</span><span\; class="notranslate">\; =</span>\mathrm{<span\; class="notranslate">\; \&eta;</span>}$

Wherein, the duty factor η of the iron core is ≥98%.

Described step (5), it also comprises the following steps:

(51) Place the mixed insulating coating: put the above-mentioned mixed insulating coating evenly stirred into the powder adding device of the automatic winding machine, and keep it at 28-35°C;

(52) Adjusting the powder adding device: according to the specifications of the non-oriented magnetic material, adjust the described powder adding device so as to control the dosage of the mixed insulating coating, so that it can be evenly coated on the non-oriented magnetic material,

(53) Coating the mixed insulating paint: continue to maintain the temperature at 28-35°C, start the powder adding device, apply the above-mentioned mixed insulating paint evenly on the surface of the non-oriented magnetic material, and make it form an insulating coating layer;

(54) Winding non-oriented magnetic material: while step (53) is being carried out, a fully automatic winding machine is started synchronously to wind the non-oriented magnetic material, so that the mixed insulating coating can be filled in time into the tiny gaps generated by the winding of the non-oriented magnetic material, and penetrate into the interior of the non-oriented magnetic material.

An iron core made by implementing the above-mentioned winding iron core preparation method, which includes a cylindrical body, characterized in that the cylindrical body is made of a strip-shaped non-oriented coating coated with a mixed insulating paint The magnetic material is wound, and the relationship formula between the space factor η, the outer diameter D, the inner diameter d, the number of winding turns n and the thickness h of the non-oriented magnetic material of the cylindrical body is as follows:

$\frac{\mathrm{<span\; class="notranslate">\; no</span>}}{<span\; class="notranslate">\; (</span>\mathrm{<span\; class="notranslate">\; D.</span>}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; d</span>}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; \&divide;</span>\mathrm{<span\; class="notranslate">\; 2</span>}<span\; class="notranslate">\; \&divide;</span>\mathrm{<span\; class="notranslate">\; h</span>}}<span\; class="notranslate">\; \&times;</span>\mathrm{<span\; class="notranslate">\; 100</span>}<span\; class="notranslate">\; \%</span><span\; class="notranslate">\; =</span>\mathrm{<span\; class="notranslate">\; \&eta;</span>}$

Wherein, the duty factor η of the iron core is ≥98%.

Wherein, the mixed insulating coating is composed of

Material A: silicon oxide with a particle size of 1800-2200 mesh,

Material B: aluminum dihydrogen phosphate with a particle size of 1800-2200 mesh,

C material: industrial alcohol;

The above-mentioned material A, material B and material C are mixed according to the weight percentage of 28-34% of material A, 28-34% of material B and 38-42% of material C, and uniformly stirred at room temperature.

The non-oriented magnetic material includes a low-carbon silicon-containing or silicon-free soft magnetic alloy material and its products provided with a single-side or double-side insulating layer.

The beneficial effects of the present invention are: the method provided by the present invention has fewer procedures, and the production can be completed by a single operation, while ensuring the accuracy and consistency of the product, greatly improving the interlayer insulation performance of the iron core, high temperature resistance, magnetic permeability and pass rate, and adopts constant pressure gas and high oil pressure method, combined with 360-degree uniform pressing and winding of non-oriented magnetic materials, and at the same time, it is evenly coated on the surface of the non-oriented magnetic material with mixed insulating paint to fully fill the non-oriented magnetic material. The tiny gaps generated by the deformation penetrate into the interior of the material, thereby improving the performance of the product as a whole; moreover, the mixed insulating coating has good insulating properties, good adhesion and corrosion resistance, and can withstand high temperatures of 740-780 ° C. During the high-temperature treatment process, the magnetic material is siliconized to ensure product quality; the iron core provided by the invention has a reasonable structure, a simple structure, can withstand high temperatures, has high interlayer insulation performance, and has a high magnetic permeability effect, and The non-oriented magnetic material can be low-carbon silicon-containing or silicon-free soft magnetic alloy material and its products with single-sided or double-sided insulating layers, which greatly reduces the production cost.

The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

Description of drawings

Fig. 1 is the three-dimensional structure schematic diagram of the present invention;

Fig. 2 is the schematic diagram of the structure cut radially in Fig. 1;

FIG. 3 is an enlarged schematic diagram of the structure of part A in FIG. 2 .

Detailed ways

Embodiment: Referring to Fig. 1, Fig. 2 and Fig. 3, a kind of winding iron core preparation method provided by the present invention, it comprises strip-shaped non-oriented magnetic material 11, and it comprises the following steps:

(1) Preparation of mixed insulating paint 12: for uniform coating on the surface of the non-oriented magnetic material 11, so as to fully fill into the tiny gaps produced by the deformation of the non-oriented magnetic material 11, and penetrate into the non-oriented The inside of the magnetic material 11, and the non-oriented magnetic material 11 can be siliconized during the high temperature treatment process;

The specific steps are as follows:

(11) Preparation raw materials:

Prepare material A: prepare silicon oxide with a particle size of 1800-2200 mesh;

Prepare material B: prepare aluminum dihydrogen phosphate with a particle size of 1800-2200 mesh;

Preparation of material C: preparation of industrial alcohol;

(12) Stirring of ingredients: the weight percentage of the above-mentioned material A, material B and material C is 28-34% of material A, 28-34% of material B and 38-42% of material C to form a mixed insulating coating 12, and stirring the mixed insulating coating 12 at room temperature;

(13) Mixing for later use: After uniformly mixing the above mixed insulating paint 12, store it at 28-35°C for later use.

(2) Feeding: Place a non-oriented magnetic material 11 on a fully automatic feeder, and tightly install and fix it for feeding;

(3) Feeding: pulling the beginning part of the above-mentioned non-oriented magnetic material 11 to a fully automatic winding machine, and positioning it for production;

(4) Setting parameters: According to the specifications of the iron core to be produced, the relevant required parameters are sequentially debugged and set on the automatic feeding machine and the automatic winding machine in advance;

The specific steps are as follows:

(41) Open the automatic control mode of the automatic feeding machine and the automatic winding machine, and enter the setting mode of each relevant parameter;

(42) Correspondingly set the feeding length, drag piece delay, pressing position, welding position, pushing time, welding time, welding delay, pushing iron core, Coil material thickness, number of winding turns, product outer diameter and product inner diameter parameters, among which the relationship formula of coil thickness h, number of winding turns n, iron core outer diameter D, iron core inner diameter d and iron core space factor η as follows:

$\frac{\mathrm{<span\; class="notranslate">\; no</span>}}{<span\; class="notranslate">\; (</span>\mathrm{<span\; class="notranslate">\; D.</span>}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; d</span>}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; \&divide;</span>\mathrm{<span\; class="notranslate">\; 2</span>}<span\; class="notranslate">\; \&divide;</span>\mathrm{<span\; class="notranslate">\; h</span>}}<span\; class="notranslate">\; \&times;</span>\mathrm{<span\; class="notranslate">\; 100</span>}<span\; class="notranslate">\; \%</span><span\; class="notranslate">\; =</span>\mathrm{<span\; class="notranslate">\; \&eta;</span>}$

Wherein, the duty factor η of the iron core is ≥98%.

(5) Production: Turn on the automatic feeding machine and the automatic winding machine, and the automatic feeding machine will deliver the non-oriented magnetic material 11 to the automatic winding machine at an even speed. The automatic winding machine uses constant pressure gas and high oil Pressing method, combined with 360-degree uniform pressing and winding of the non-oriented magnetic material 11, to form a cylindrical body 1;

Specifically, the following steps are included:

(51) Place the mixed insulating coating 12: put the above-mentioned mixed insulating coating 12 evenly stirred into the powder adding device of the automatic winding machine, and keep it at 28-35°C;

(52) Adjust the powder adding device: according to the specifications of the non-oriented magnetic material 11, adjust the described powder adding device so as to control the dosage of the mixed insulating coating 12, so that it can be evenly coated on the non-oriented magnetic material 11;

(53) Coating the mixed insulating paint 12: continue to keep at 28-35°C, start the powder adding device, apply the above-mentioned mixed insulating paint 12 evenly on the surface of the non-oriented magnetic material 11, and make it form an insulating coating;

(54) Winding the non-oriented magnetic material 11: while step (53) is being carried out, a fully automatic winding machine is started synchronously to wind the non-oriented magnetic material 11, so that the mixed insulating coating 12 It can be filled into the tiny gaps generated by the winding of the non-oriented magnetic material 11 in time, and penetrate into the non-oriented magnetic material 11 .

The above steps (1) to (4) are in no order.

An iron core manufactured by implementing the aforementioned winding iron core preparation method, which includes a cylindrical body 1, characterized in that the cylindrical body 1 is made of a strip-shaped insulating coating 12 coated on the surface The non-oriented magnetic material 11 is wound, and the relationship formula between the space factor η, the outer diameter D, the inner diameter d, the number of winding n and the thickness h of the non-oriented magnetic material 11 of the cylindrical body 1 is as follows:

$\frac{\mathrm{<span\; class="notranslate">\; no</span>}}{<span\; class="notranslate">\; (</span>\mathrm{<span\; class="notranslate">\; D.</span>}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; d</span>}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; \&divide;</span>\mathrm{<span\; class="notranslate">\; 2</span>}<span\; class="notranslate">\; \&divide;</span>\mathrm{<span\; class="notranslate">\; h</span>}}<span\; class="notranslate">\; \&times;</span>\mathrm{<span\; class="notranslate">\; 100</span>}<span\; class="notranslate">\; \%</span><span\; class="notranslate">\; =</span>\mathrm{<span\; class="notranslate">\; \&eta;</span>}$

Wherein, the duty factor η of the iron core is ≥98%.

The mixed insulating coating 12 consists of

Material A: silicon oxide with a particle size of 1800-2200 mesh,

Material B: aluminum dihydrogen phosphate with a particle size of 1800-2200 mesh,

C material: industrial alcohol;

The above-mentioned material A, material B and material C are mixed according to the weight percentage of 28-34% of material A, 28-34% of material B and 38-42% of material C, and uniformly stirred at room temperature.

The non-oriented magnetic material 11 includes low-carbon silicon-containing or non-silicon-containing soft magnetic alloy materials and products thereof provided with single-side or double-side insulating layers.

The non-oriented magnetic material 11 used in this embodiment is H series cold-rolled non-oriented silicon steel sheet, its model is H250-H1300, and its thickness h is 0.1-0.5 mm; in other embodiments, the non-oriented silicon steel sheet can also be Low-carbon silicon-containing or silicon-free soft magnetic alloy material with single or double-sided insulating layers and its products. Under the computer programming control of the automatic feeding machine and automatic winding machine, the constant pressure air pressure and high oil pressure method, combined with 360-degree uniform pressing, accurately controls the production of the iron core, and there is almost no gap between the layers of silicon steel that make up the iron core. gap, and with the coating of mixed insulating coating 12, the test shows that the performance of the iron core can be improved by 35-40%, and the mixed insulating coating 12 has good insulation performance, good adhesion and corrosion resistance, and can withstand 740-780 °C High temperature, and can perform siliconizing operation on non-oriented silicon steel sheet during high temperature treatment to ensure product quality.

As described in the above-mentioned embodiments of the present invention, all other preparation methods and iron cores obtained by using the same or similar combinations or methods are within the protection scope of the present invention.

Claims (4)

1. A winding iron core preparation method, the iron core comprises a strip-shaped non-oriented magnetic material, is characterized in that, it comprises the steps: (1) Preparation of mixed insulating paint: used to evenly coat the surface of the non-oriented magnetic material, so as to fully fill into the tiny gaps produced by the deformation of the non-oriented magnetic material, and penetrate into the interior of the non-oriented magnetic material , and siliconize the non-oriented magnetic material during the high temperature treatment process; (2) Feeding: Place a non-oriented magnetic material on the automatic feeder, and fix it tightly for feeding; (3) Feeding: Pull the beginning part of the above-mentioned non-oriented magnetic material to the automatic winding machine, and position it for production; (4) Setting parameters: according to the specifications of the iron core to be produced, debug and set the relevant parameters in sequence on the automatic feeding machine and automatic winding machine in advance; (5) Production: Turn on the automatic feeding machine and automatic winding machine, and the automatic feeding machine will deliver the non-oriented magnetic material to the automatic winding machine at an even speed. The automatic winding machine uses constant pressure gas and high oil pressure combined with 360-degree uniform pressing and winding of the non-oriented magnetic material to form a cylindrical body. 2. according to the described winding iron core preparation method of claim 1, it is characterized in that, described step (1), it also comprises the following steps: (11) Preparation raw materials: Prepare material A: prepare silicon oxide with a particle size of 1800-2200 mesh; Prepare material B: prepare aluminum dihydrogen phosphate with a particle size of 1800-2200 mesh; Preparation of material C: preparation of industrial alcohol; (12) Stirring of ingredients: The weight percentages of the above-mentioned material A, material B and material C are 28-34% of material A, 28-34% of material B and 38-42% of material C to form a mixed insulating coating, and Stir the mixed insulating coating at room temperature; (13) Mixing for later use: After uniformly mixing the above mixed insulating coatings, store them at 28-35°C for later use. 3. according to the described winding iron core preparation method of claim 1, it is characterized in that, described step (4), it also comprises the following steps: (41) Open the automatic control mode of the automatic feeding machine and the automatic winding machine, and enter the setting mode of each relevant parameter; (42) Correspondingly set the feeding length, drag piece delay, pressing position, welding position, pushing time, welding time, welding delay, pushing iron core, Coil material thickness, number of winding turns, product outer diameter and product inner diameter parameters, among which the relationship formula of coil thickness h, number of winding turns n, iron core outer diameter D, iron core inner diameter d and iron core space factor η as follows: $\frac{\mathrm{<span\; class="notranslate">\; no</span>}}{<span\; class="notranslate">\; (</span>\mathrm{<span\; class="notranslate">\; D.</span>}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; d</span>}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; \&divide;</span>\mathrm{<span\; class="notranslate">\; 2</span>}<span\; class="notranslate">\; \&divide;</span>\mathrm{<span\; class="notranslate">\; h</span>}}<span\; class="notranslate">\; \&times;</span>\mathrm{<span\; class="notranslate">\; 100</span>}<span\; class="notranslate">\; \%</span><span\; class="notranslate">\; =</span>\mathrm{<span\; class="notranslate">\; \&eta;</span>}$ Wherein, the duty factor η of the iron core is ≥98%. 4. according to the described winding iron core preparation method of claim 1, it is characterized in that, described step (5), it also comprises the following steps: (51) Place the mixed insulating coating: put the evenly stirred mixed insulating coating into the powder adding device of the automatic winding machine, and keep the mixed insulating coating at 28-35°C; (52) Adjusting the powder adding device: according to the specifications of the non-oriented magnetic material, adjust the described powder adding device so as to control the dosage of the mixed insulating coating, so that it can be evenly coated on the non-oriented magnetic material; (53) Coating the mixed insulating paint: continue to keep the mixed insulating paint at 28-35°C, start the powder adding device, apply the above-mentioned mixed insulating paint evenly on the surface of the non-oriented magnetic material, and make the It forms an insulating coating; (54) Winding non-oriented magnetic material: while step (53) is being carried out, a fully automatic winding machine is started synchronously to wind the non-oriented magnetic material, so that the mixed insulating coating can be filled in time into the tiny gaps generated by the winding of the non-oriented magnetic material, and penetrate into the interior of the non-oriented magnetic material.

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