CN105895323A - Three-phase energy saving transformer with unlaminated core and zero-clearance magnetic circuit - Google Patents

Abstract

The invention provides a three-phase energy saving transformer with an unlaminated core and a zero-clearance magnetic circuit. The three-phase energy saving transformer is a multi-technology with improved structure and process in the field of medium and large transformer manufacturing. The zero-clearance magnetic circuit is arranged to obtain the lowest iron loss and lowest man-hour and manufacturing cost. By the technology of replacing a laminated core with a wound core, the round cross-section core and a rectangular cross-section yoke can obtain the optimal process fitting; the core laminating cost is reduced; the magnetic loss is reduced; the three-phase energy saving transformer is suitable for manufacturing of a core-type or shell-type three-phase transformer of which the power is from tens of kilowatts to hundreds of thousands of kilowatts, and is a significant innovation in the transformer structure and the process technology.

Description

Non-laminated iron-core zero clearance magnetic circuit three-phase energy-saving transformer

Invention field

The invention belongs to the transformer technology field in electricity, relate to magnetic structure and the manufacture of transformator Technique, specifically, is the energy-economic transformer creating a kind of new construction new technology.

Background technology

The ultimate principle of transformator is by electromagnetic induction, and one alternating voltage is changed into another electricity Pressure, its basic structure is circuit (including winding and external circuit) and the interlinkage of magnetic circuit, to realize electric energy Mutual conversion with magnetic energy.For reducing magnetic energy loss, unshakable in one's determination generally being folded by blocks of thin silicon steel plates and Becoming, winding will be put magnetic circuit into, magnetic circuit is necessary for sectional making and reserves opening, is then inserted into winding, Remake sealing to process, magnetic circuit necessarily stays many air gaping of joints be referred to as magnetic circuit gap, magnetic Although gap, road is the least, but because the permeability of air is far below ferromagnetic material, so air-gap magnetic circuit Magnetic resistance is the biggest, it is necessary to certain exciting current, in order to increase magnetomotive force to overcome magnetic resistance, also That is, it is necessary to increase exciting current.Strengthen exciting current and i.e. mean to increase the unloaded damage of transformator Consumption；It addition, in conventional three-phase transformator, core section is circular, by the lamination stack of different in width Circular, not as the rectangle lamination cross section of iron yoke folds conveniently, technique is especially complex, fold require non- Chang Yange, the man-haur efficiency making manufacture transformator is the lowest.

In a word, it is big to there is open circuit loss in existing transformator, and process structure is complicated, and manufacturing cost is high, has Treat that major design improves.

Summary of the invention

The purpose of the present invention, is to be improved by structure, simplifies transformator stacking technique, and reduction is manufactured into This；Reduce loss, improve efficiency, realize the reducing energy consumption of transformer device structure and technique.The present invention relates to And the significant improvement of the magnetic structure of transformator, the novelty of lamination process simplifies.

The present invention initially with the structure different with existing traditional transformer and process route, that It is exactly transformator new construction and the novel technique of zero clearance magnetic circuit, relevant zero clearance magnetic structure technology And technique, refer to Chinese invention patent application 201310160702.1 " the self-styled closed form of zero clearance magnetic circuit Transformator ", the present invention is based on this invention, to entering that three-phase transformer structure and technique are made One step technological improvement.

Traditional transformer, by the guarantee of fine stacking technique, is allowed to the profile meeting winding and minimum Magnetic circuit gap.But result is, although change the biggest time cost, still no-load current cannot be dropped to Lower level.

Small-sized E type transformator is from there being the evolution to c-type transformator of the gap magnetic circuit, and it substantially will High-power transformer, to the conversion of precision machined zero clearance magnetic circuit, is enlightened in uncontrollable magnetic circuit gap Too can be from artificial hand work closed assembly to the improvement of zero clearance magnetic circuit.In order to make iron core and iron yoke Faying face zero clearance closely cooperates, in addition to faying face polish is processed by needs, and how could be in reality Unshakable in one's determination magnetic circuit gap with iron yoke faying face is decreased or even eliminated in the transformator of border, how to utilize zero clearance The peculiar structure of magnetic circuit, combines the new construction that original lamination cannot use, should structure letter Single reasonable, easy construction is easy again, the most prior and final result, is also intended to reach transformation The efficient energy-saving of device and two big targets of reduction assembly cost.

The present invention is achieved in that and a kind of is mainly made up of winding, iron core and iron yoke three parts Three-phase transformer, is characterized in that, iron core is non-laminated type circular cross-section structure；Iron yoke is silicon steel sheet stack mould assembly square Tee section structure；Zero clearance magnetic structure is constituted between iron core and iron yoke.

The solution have the advantages that it will be evident that first the new construction of zero clearance magnetic circuit can be effective Reduce transformer magnetic circuit gaping of joints, reduce magnetic resistance, make transformator have less open-circuit excitation electric current And iron loss, improve the efficiency of transformator；Secondly, use the iron core of circular section, same cross-sectional area and The winding of the identical number of turn, the conductor length of circular section winding is the shortest, and resistance is minimum, can reduce transformation The copper loss of device；And owing to using zero clearance magnetic structure, split possible with iron yoke unshakable in one's determination manufactures closed assembly, Iron core just can use non-laminated type to replace closed assembly lamination, thus reduces manufacture difficulty and the work of transformator Shi Chengben.

Accompanying drawing explanation

Fig. 1, the structure chart of existing conventional three-phase core type transformer magnetic circuit one lamination sheets.

Fig. 2, existing conventional three-phase core type transformer magnetic circuit core profile.

Fig. 3, the member profile schematic diagram of zero clearance magnetic circuit three-phase core type energy-economic transformer of the present invention.

Fig. 4, the monnolithic case schematic diagram of zero clearance magnetic circuit three-phase core type energy-economic transformer of the present invention.

Fig. 5, partial longitudinal section with spill circular groove iron yoke.

Fig. 6, partial cross-sectional view unshakable in one's determination with spill circular groove iron yoke.

Fig. 7, rewinding material produce the analyzing chart for reason of vortex flow.

Fig. 8, the rewinding material appearance schematic diagram manufactured.

Fig. 9, commodity orientation coiled material cutting line chart.

Figure 10, different commodity orientation sheet material cutting line chart.

Figure 11, the construction profile schematic diagram of zero clearance magnetic circuit three-phase shell type transformer of the present invention.

Detailed description of the invention

The transformer magnetic circuit structure definition of the present invention is different from traditional transformer, it is necessary to separately define.

In the present invention:

(1) unshakable in one's determination: only refer to the magnetic device being in winding.

Winding (2): refer to the current source of transformator, is the device that flows into and out of transformer alternating electric current.

Iron yoke (3): refer to make in transformator the magnetic current in iron core to be interconnected, complete the magnetic in loop Device.

Magnetic circuit: refer to the magnetic linkage of transformator, be the whole magnet of transformator, including iron core, iron yoke General name.

In traditional transformer:

Heart portion: also referred to as core, stem, stem stem, is equivalent to the iron core (1) of the present invention.

Yoke portion: also referred to as yoke, refers to the device making iron core complete magnetic linkage in transformator, including upper yoke, Lower yoke, may also have return yoke, is equivalent to the iron yoke (3) of the present invention.

Iron core: refer to the magnetic linkage of transformator, including whole magnet total in transformer core portion and yoke portion Become, be equivalent to the magnetic circuit of the present invention.

Winding (2): also referred to as coil, defines identical with the winding of the present invention (2).

Employing redefines in order to circle of good definition another edition of a book inventive structure is conceptive and prior art Difference, prevent from obscuring.Winding (2) definition in the present invention is identical with traditional transformer, but ferrum The title of the heart is far from each other with tradition, and traditional iron core refers to whole magnetic device, include heart portion and Yoke portion.Traditional three-phase transformer, although formed by many lamination closed assemblies, but heart portion is with yoke portion even Become common flux path, indivisible, so iron core also becomes transformer core portion and the general name in yoke portion.And Definition unshakable in one's determination in the present invention only refers to the magnetic device being in winding, is equivalent in traditional definition Why heart portion, redefine, it is therefore an objective to be diverse process route, because will pass Iron core fractionation in system definition becomes the iron core in this definition and adds the big parts of upper yoke two, it is possible to will The closed assembly process that the heart portion of original traditional transformer and yoke portion are combined, is improved to the ferrum of the present invention The heart and iron yoke closed assembly respectively, thus the difficulty during traditional handicraft is operated, and cannot ensure in quality The big drawback of the two of precision, can be transferred through zero clearance of the present invention magnetic structure technology and is overcome Improve.So the transformator technique of the present invention and structure, it is belonging to the innovation and creation of initiative, therefore Must define with different structures to show difference.

In the stacked transformator in widely used, conventional thought always considers transformer core portion Link together consideration with yoke portion, mutually can be made up at gaping of joints by lamination coordinated transposition Magnetic resistance.But in concrete practice, this idea both can not be greatly decreased gap magnetic resistance, causes again The very complicated of stacking technique, time-consuming.

In conventional small single-phase transformer, in order to reduce the open circuit loss of transformator, small-sized single-phase Transformator, from magnetic circuit gap uncontrollable E shape stalloy, inserts the core structure of winding, by The technique that iron core consistency also cannot ensure, develops the zero clearance magnetic circuit of c-type transformator, then sends out Ring-shaped transformer and the R type transformator of gapless magnetic circuit is arrived in exhibition, it may be said that greatly reduce air gap magnetic Resistance, reduces open circuit loss.And existing a large amount of conventional three-phase transformator, its technique or lamination Technique, it should also rest in the pattern that blade inserting E type single-phase transformer is similar, be not the most similar to C The zero clearance magnetic circuit of type transformator occurs in three-phase transformer, causes the transformer noload losses cannot It is greatly reduced, here it is the basic concept of the innovation direction zero clearance magnetic circuit of the present invention, by ferrum Faying face between the heart and iron yoke is worked into the size of precision, the most permissible just as c-type transformator The structure realizing zero clearance magnetic circuit is improved.

It is to say, copy the idea of the zero clearance magnetic circuit of single-phase c-type transformator, by three phase-change pressure The iron core of device separates closed assembly with iron yoke, is then then assembled into product, is combined closed assembly both replacing Traditional method, replace the accurate closed assembly of traditional transformer with the polish of they faying faces, both may be used So that magnetic resistance loss is greatly reduced, stacking technique can be greatly simplified again, reduce difficulty and the cost of closed assembly.

Fig. 1 show the structure chart of existing conventional three-phase core type transformer iron circuit one lamination sheets. Installing three windings on three stem stems, just become a three-phase core type transformer, it compares congenerous Three single-phase transformers save magnetic circuit material, extensively should so obtaining in the three-phase voltage system of the whole world With.In Fig. 1, the cut-parts of three kinds of specifications, it is combined into a lamination sheets, first with the two to three of the left side Sheet closed assembly, then with two to three closed assemblies on the right, until being laminated to the thickness of regulation, the most this Iron core is square-section, and required winding is also rectangle.But, the use of the rectangle winding of same cross-sectional Copper amount is at least 1.13 times of circular winding, and the most uneconomical, copper consumption is many more means winding resistance Value increase, so load loss is big, adds lamination gap greatly, and no-load current increases, unloaded damage Consumption is also big, and the efficiency of transformator reduces, and therefore, heart portion is not typically designed to rectangle and majority uses Circular.It is crucial that circular heart portion unshakable in one's determination needs the sizes cut-parts using width different, so Cutting and closed assembly will be greatly increased man-hour, the biggest manyfold of difficulty of closed assembly.

In the manufacturing process of circular section core, because the gap between lamination and winding tube is the least, So relating to core-lamination stack closed assembly to cross range request very strictly, first it is to improve assembly precision, to protect Card product has the magnetic circuit gap of minimum, and secondly, heart portion to be ensured builds up the circle of an approximation and cuts Face.In order to prevent deformation, the generation of the situation such as crooked, often fold one layer, the most each folded all Need to carry out the correction at lamination position, repair, measure.During closed assembly, certain in order to ensure Closed assembly speed, it is necessary to have lamination people and pass sheet people, at least want 9 people jointly to participate in 1 power also The not very closed assembly work of the biggest transformer core, guarantee work efficiency.So labor waste Very big, finally, also colligation, stand up, inserted sheet, dry, insulate, sealing etc. technical process, Each operation is taken a lot of work time-consumingly the most very much.

Fig. 2 is existing conventional three-phase core type transformer magnetic circuit core profile.Showing in figure, heart portion is Circular section, and yoke portion is rectangular configuration.

Zero clearance magnetic circuit in the present invention is characterized in that, unshakable in one's determination and iron yoke dissociated operation, Each being fabricated separately and become individual components, then iron core is whole with the third individual components winding again Synthesize intergrant, finally iron core winding intergrant and iron yoke split are assembled into whole transformator. So the magnetic circuit of the present invention is divided into two main parts iron cores and iron yoke, with traditional concept Different.Why both are separated, it is important to such a separating technology, iron yoke will be made to fold Process of assembling is greatly simplified, almost without the difficulty of technique, also almost without closed assembly required precision.With Time, the very simple operating winding of iron core, become circular section easy than traditional handicraft lamination.Last Assembling, this point is also difficult to traditional handicraft with stating, because new technology ensures transformer device structure precision Method, be only that in the polish of faying face between them, this polish is again tradition work Skill is unexistent.

The process of conventional three-phase transformator is equivalent to unshakable in one's determination alleged by the present invention and iron yoke are placed on one Playing in addition closed assembly, closed assembly complexity and less economical, separately closed assembly, cost is greatly reduced naturally.

Summing up described above, all architectural features of the present invention are:

1, the non-laminated iron-core (1) in magnetic circuit is to be wound by soft iron or filled by magnetic powder to form, respectively Being referred to as convoluted or filled-type, iron core is the independent separate body parts of circular section；

2, iron yoke (3) completed by silicon steel laminations closed assembly, square-section independent separate body parts；

3, winding (2) and (1) unshakable in one's determination overall middle individual components being also integrated before total assembling；

4, having the faying face through polish between iron core (1) and iron yoke (3), faying face is zero public affairs Difference coordinates, and is configured to zero clearance magnetic structure.

Fig. 3 is the member profile figure of the three-phase core type energy-economic transformer of the present invention.It is characteristic of the invention that will Parts are clearly divided into three major types parts: (1) unshakable in one's determination, winding (2) and iron yoke (3), this structure Being clearly distinguishable from existing conventional transformer structure and technique, (1) unshakable in one's determination and iron yoke (3) have two Faying face A and B, A are the faying face on three tops unshakable in one's determination and upper yoke, B be three unshakable in one's determination Bottom and the faying face of lower yoke.From this point this it appears that the district of the present invention and traditional structure Not, because traditional structure is to be considered as unified structure by whole magnetic circuit, it is that heart portion and yoke portion are existed The unified structure assembled together in technique and operate is overall.

In the present invention, iron yoke (3) considers as the connector between iron core, to complete the company of magnetic circuit Logical, iron yoke is the stalloy cut-parts of square-section, and each cut-parts width is identical, length is different, in order to Form two semi-cylindrical at iron yoke two ends, the circular columns covering two side column phases is unshakable in one's determination.At this In bright, iron yoke silicon steel cut-parts are rectangle, and the width of cut-parts is identical and length is different.

In Fig. 3, (1) unshakable in one's determination, winding (2) and iron yoke (3) are as three big parts, three big portions Part is the most separately machined, and part assembles, and the most always dresses up the three-phase transformer product of Fig. 4.(1) unshakable in one's determination It is labeled as A, (1) unshakable in one's determination and the faying face mark of lower yoke (3) with the faying face of upper yoke (3) Note is B, and these planes are required for making polish, to realize zero clearance magnetic circuit.

Fig. 4 is the monnolithic case figure of the three-phase core type energy-economic transformer of the present invention.This figure is also a kind of signal Figure, eliminates many minor components in figure.

The method of manufacturing technology unshakable in one's determination of energy-economic transformer of the present invention is as follows:

1, manufacture unshakable in one's determination

The non-laminated iron-core of the present invention mainly has two kinds of convoluted iron cores and filled-type unshakable in one's determination, and division is such as Under:

1.1, convoluted iron core

Sawing sheet: output the coil band more slightly wider than required interferric width, coil band from big cylinder coiled material Leave in charging tray；

Dead axle: insert the insulation mandrel of a minor diameter in tape handler, plug has a breach, Calibration axle center；

Uncoiling: coil headed is properly inserted breach, starts winding；

Winding: harmonize at any time position, pulling force and winding speed, until it reaches required core-diameter, End band is fixing, in case of the coil band in a charging tray is finished, can connect the coil band in another charging tray Continue winding；-

Bonding or solidification: after having wound, make each layers cementing unshakable in one's determination together, will not fall apart, Or make each layer winding in iron core be mutually bonded firmly, for example with similar insulation electromagnetic wire by thermosetting method In make coil shape thermosets be coated in strip, winding terminates post-heating makes solidification unshakable in one's determination；

Fluting: after boning or solidifying, can at least open a stria in appearance unshakable in one's determination vertically, Groove should from winding while reaching another side, the degree of depth reaches insulation mandrel, it is therefore an objective to chop strip off Continuous electrical connection；Such as large-scale iron core, it may be necessary to open a plurality of groove；

Insulation processing: in notch remove metal fillings, notch bare metal go out part aoxidize, nitrogenize or Other insulation processing, to generate insulant, makes each interlayer of winding not be electrically connected；

If insulation mandrel is hollow-core construction.Magnetic conduction pad or implant can be inserted in space in plug, Increase magnetic conduction sectional area；

Fixing: notch is fixed, and increases the fastness of whole iron core.

Material for rewinding material has high permeability ultra-thin cold rolled silicon steel band, permalloy soft magnetic strip The soft magnetic materials such as material or amorphous core band.

The thickness of silicon strip is 0.18～0.30；The thickness of permalloy tape is 0.03～0.10mm；Non- Brilliant tape thickness unshakable in one's determination is 0.03mm.

Amorphous core can be by Fe-based amorphous alloy, ferrum ni-based amorphous alloy, cobalt base amorphous alloy or receive The materials such as rice non-crystaline amorphous metal are constituted, and wherein Fe-based amorphous alloy price is low, yield is high, is relatively suitable for Industrial Frequency Transformer uses.

Fe-based amorphous alloy is to be made up of 80%Fe and 20%Si, B metalloid element, and it has height Saturation induction density (1.54T), the everyway such as pcrmeability, exciting current and iron loss is better than silicon The feature of steel disc, particularly iron loss low (for the 1/3-1/5 of grain-oriented Si steel sheet), replace silicon steel to do and join Piezoelectric transformer can save energy 60-70%.The thickness of strip of Fe-based amorphous alloy is about 0.03mm, extensively General it is applied to distribution transformer, high power switching power supply, pulse transformer, magnetic amplifier, intermediate frequency Transformator and inverter iron core, be suitable for 10kHz frequencies below and use.

Owing to super chilling solidifies, during alloy graining, atom has little time ordered arrangement crystallization, and obtain consolidates State alloy is longrange disorder structure, does not has the crystal grain of crystal alloy, crystal boundary, referred to as amorphous Alloy, a revolution of metallurgical material of being known as.This non-crystaline amorphous metal has many uniquenesses Performance, such as excellent magnetic property, corrosion resistance, wearability, high intensity, hardness and toughness, height Resistivity and mechanical-electric coupling performance etc..Due to it excellent performance, technique simple, from the eighties Start to become the research and development emphasis of domestic and international material supply section educational circles.

Amorphous core generally also by metallurgical material factory strip coil around forming, with the manufacture of convoluted iron core Method is identical.A large amount of productions from now on are likely by the dimensions of transformer factory's requirement, by metallurgical material Material factory directly provides the iron core of given size, it is possible to take powder compression or powder metallurgy mode to manufacture.

1.2, filled-type is unshakable in one's determination

Filled-type iron core technique be ferromagnetic type powder and insulant are uniformly mixed after, fill online In circle cylinder, compacting is fine and close or presses the iron core that powder metallurgical technique is constituted, and more can save and wind man-hour. The nanometer using nanometer powder to constitute is unshakable in one's determination, and crystal grain is less, is lost lower.

2, winding manufacture, technical process is identical with existing traditional handicraft, is not illustrated.Winding manufactures After completing, winding being inserted in iron core, integral core solidifies together with winding dipping lacquer.

3, iron yoke manufacture

Obtain several various sizes of iron yoke cut-parts by cutting device, iron yoke cut-parts be same width but One group of stalloy of different length；

Due to the independent closed assembly of iron yoke, closed assembly more common than traditional iron core and iron yoke is simple and convenient much. Tradition is stacked as horizontal closed assembly, and cut-parts are horizontal positioned, layer upon layer of, and press against above is following, Even if finding closed assembly deviation, it is also difficult to adjust, and severe deviation, in addition to doing over again, is difficult to use other means Corrected.The closed assembly of the present invention then uses vertical closed assembly, the action of gravity of cut-parts on platform, Will not press against each other, as long as the cut-parts of different length sequentially to be inserted the iron yoke group on assembly platform In framing up, the yardstick of frame is more than cut-parts width, being very easy to so inserting, treating that whole cut-parts are inserted After, it is possible to arranged adjustment.Then the vertical push plate level of assembled frame is advanced, progressively to sanction Sheet is pushed, and as found, cut-parts have irregular situation about stacking, and can unclamp adjustment at any time, until reaching The shape wanted to design, so the iron yoke closed assembly of the present invention can reach more smart than traditional closed assembly Close and fine and close degree.

Finally, cut-parts closely overlap that to become a two be semi-cylindrical rectangular cubic, and tie up Prick bonding sealing.The method of colligation is similar to tradition, is not described herein, and is bonded with multiple method, its In example be to use hot-setting adhesive or claim thermosetting paint, after closed assembly terminates molding, made by heating Iron yoke solidifies.

One transformator needs two iron yoke upper yokes and lower yoke, the size of two iron yokes, Profile is identical.

In three-phase transformer, commonly used oriented electrical steel, the permeability of oriented electrical steel High, magnetic loss is less than oriented electrical steel.In iron core, high magnetic conduction direction flows to all with the magnetic line of force For axially, i.e. vertical direction shown in Fig. 4.In iron yoke, high magnetic conduction direction is then horizontal direction.

4, faying face polish

Three windings above-mentioned operation formed are inserted in three iron cores respectively, to form three iron cores Individual components in the middle of winding association, and solidify.Then faying face A and the combination to two ends unshakable in one's determination Face B is refined to the planar dimension precision of regulation；The faying face of iron yoke is refined to phase the most respectively The planar dimension precision answered, component processing waits general assembly after completing.

Before assembling, first the iron core after processing polishes and iron yoke composition surface being made insulation processing increases Contact resistance, to reduce the probability of sensing circulation.The method that surface insulation processes be make unshakable in one's determination and Yoke contact surface burning, nitrogenize or generate a thin layer dielectric cover stalloy gold On genus, make the magnetic property of faying face be subject to the most impacted less, and electric conductivity is contained, from And limit issuable eddy current.

5, general assembly

Being lain in by lower yoke on mounting platform, the faying face B of lower yoke is upward；

After in the middle of three compositions, the winding association unshakable in one's determination of individual components is located equidistant, overall peace It is placed on lower yoke B face；

By the faying face A of upper yoke towards lower cover on three winding iron cores；

Securing bracket is finally installed, with securing member such as fastening bolt bolt locking bracket, whole installs Become.

In order to strengthen fastness, also faying face precoating solidification glue can be also had herein below before assembling Narration.

5, other adnexa is installed

The programs such as such as wiring, the installation of the accessory such as radiator, sensor, and test are pressed Common process is constructed, and does not makes difference narration herein.

Due to the effect of gravity, upper yoke pushes down iron core, and iron core pushes down again lower yoke, so combining Face can be very tight, strains through fastening bolt, and transformator entirety reaches close and firm and connects, it is achieved Zero clearance magnetic Circuit Design requirement.

Can draw according to above-mentioned process and it is a feature of the present invention that folding respectively with unshakable in one's determination and iron yoke Dress replaces the common closed assembly of magnetic circuit；Fixed with the precision that unshakable in one's determination and iron yoke faying face polish replaces magnetic circuit Position closed assembly.

If needing higher fastness, can be first to unshakable in one's determination and iron yoke faying face before assembling It is coated with a thin layer strong adherence firming agent, then terminate in installation, after firming agent solidification, at securing member With under the common effect of firming agent, fastness is strengthened.Use the firming agent of nano material, property Energy effect is more preferable.Firming agent should have suitable heat resistance, prevents in transformator running Heating affect its cementability.It is not added with firming agent and is conducive to repairing from now on, but bond strength is low, Likely producing noise, add firming agent and be unfavorable for repairing from now on, but bond strength is high, noise is also Little, can require rationally to be selected according to different capacity and different use.

Finishing stage with iron yoke faying face unshakable in one's determination, will directly influence the size of faying face magnetic resistance, Except faying face grind as minute surface smooth in addition to, undeniable, if with microscope observe, still Certain out-of-flatness gap can be left, unless with the highest Ultra-precision Turning of cost, still may send out The trickle pit of existing many, pit can block magnetic current, increases magnetic resistance and iron loss.

In order to preferably reduce the magnetic resistance of faying face, magnetic conductivity microgranule can be added in firming agent, These magnetic conduction microgranules are probably inorganic magnetic conductor, it is also possible to organic magnetic conductor, particularly nanometer are led Magnet, performance is more preferable, and nanometer magnetic conductor is tiny due to granule, can only flow into before firming agent solidifies Pit, it is impossible to embedding increase gap width in the planes.

The another kind of method strengthening transformator firmness or increase faying face magnetic conductance is to use with spill The iron yoke of circular groove.

Fig. 5 is the partial longitudinal section with spill circular groove iron yoke.In the iron yoke of cured, The faying face of the installation site of each iron core cuts out a spill, bottom be the circle of plane Groove (31), the diameter of groove, slightly larger than iron core, is equivalent to a flat pit, and the end, hole is unshakable in one's determination and iron yoke Combination plane, and make polish.The depth visual structure of circular groove (31) needs to select, the most shallow The not flat bed on surface of may just shooting off, the deepest 1～2% (the i.e. cut-parts width the most just accounting for the iron yoke degree of depth Degree), thus little on the impact of iron yoke magnetic property.But such a sinks to structure, pass through firming agent Adhesion, it is easier to securely iron core is fixed in iron yoke, is filled in the firming agent in groove Permeability magnetic material dissipates in groove, is also easier to reduce magnetic resistance and leakage field.Meanwhile, with spill circular groove Iron yoke also can reduce the processing capacity of iron yoke, because originally must be to whole iron yoke faying face plane essence Processing, processes as long as now the iron yoke in the little area in local on three circle positions unshakable in one's determination being made polish, Processing capacity substantially reduces.

Fig. 6 is the partial cross-sectional view unshakable in one's determination with spill circular groove iron yoke, from cross sectional view it can be seen that Cross section circle size unshakable in one's determination should be less than the diameter of circular groove in iron yoke and (observes for convenience, event in figure Anticipate and groove diameter expanded), solidification glue and magnetic can just be accommodated in such a trickle circular rings Property granule.Simultaneously it is found that the design width with the iron yoke of spill circular groove is naturally larger than iron core Width, just can cover iron core, form circular groove type little Chi, the solidification glue being contained in groove and magnetic Grain, is difficult to overflow, can reduce magnetic resistance and leakage field more.Upper and lower two iron yokes, width is more than Iron core, just like medicated cap and shoes, covers iron core, profile also better appearance.But, such set Meter need to increase certain iron yoke cost, therefore, it is no employing spill circular groove iron yoke, and spill circle The projected depth of channel yoke, width, should weigh the advantages and disadvantages according to the cost performance of specific product, fit out Appropriate judgement.

The first-elected circle of core section shape in the present invention, reason is that the girth of circular cross-section is minimum, Advantageously reducing winding resistance and load loss, meanwhile, the copper consumption of winding is the most minimum, economy High.But, if circular with silicon steel sheet stack as traditional transformer, the dimensions of cut-parts Too much, so the circle of many rectangular edges proximate composition can only be constituted with limited not sizes cut-parts, Unless there are the cut-parts from the least to various sizes of diameter width, could constitute one real Circular.But, wound core is but the cylinder of a very standard, and its cross section activity coefficient is higher than Laminated core, is especially more than traditional laminated core.

It is reported, conventional coiled iron core be usually used in transformer, magnetic amplifier, earth leakage protective device, The devices such as Transformer.Structure in the present invention, may be used for high-power transformer.

According to producer's data, coiled iron core has the following advantages for Transformer:

1) in the case of condition is identical, coiled iron core is compared with tradition closed assembly iron core, and zero load is damaged Consumption declines 7%～10%；No-load current can decline 50%～75%；

2) Wound core can use the thinnest high magnetic conduction cold-reduced silicon sheet, can produce more low-loss Transformator；

3) Wound core good manufacturability, does not shear waste material, and utilization rate is almost 100%；Also can adopt With do mechanization operation, eliminating closed assembly operation, production efficiency improves 5～10 times than closed assembly iron core；

4) coiled iron core self is an entirety, is not required to supporter and is fixedly clamped, again neither one Seam, therefore with under closed assembly iron core similarity condition, transformer noise can reduce by 5～10dB.

The present invention is it would be possible to use rewinding material structure in more capacity transformator.

Certainly, the rewinding material of the coiled iron core used and the present invention had both had points of resemblance and had also had Difference, something in common is that stock is the same；And it is a difference in that the volume being in tradition Closed magnetic path is often made around iron core, so winding is difficult to put in, and the rewinding material in the present invention, It is not the magnetic circuit closed, only plays the effect unshakable in one's determination of present invention definition, it is necessary to be equipped with iron yoke, Just can complete flux path.

Additionally, three-phase transformer of the present invention, power can be much larger than original use takeup type The Transformer of iron core.

It can however not ignore, rewinding material has the biggest defect, that is, the whirlpool electricity in iron core Flow problem.So it may first have to solve the eddy current problems of rewinding material, rewinding material just can be made to reach The requirement of practicality.

Fig. 7 is the analyzing chart for reason that rewinding material produces vortex flow.It can be seen that rewinding material Also correspond to winding be wrapped on iron core, and magnetic field is just in its internal core portion enclosed, at this moment Iron core not only allow for magnetic current and flow up and down, itself is also a kind of " winding ", " winding " institute coupling The magnetic current closed is exactly the magnetic current closed in this circle " winding " is justified, more outer layers, the magnetic current of closing The most, the voltage of sensing is the highest.For that circle rewinding material outermost, every circle of 1MVA tri-phase transformation Voltage is likely to be breached even more than 10V, owing to being connected in series, if using thickness is 0.20mm's Stalloy, the voltage of outer layer 2mm interlayer unshakable in one's determination is it is possible to up to hectovolt, and whole continuous print volume ferrum Heart induced voltage from nexine to outer layer will up to ten thousand lie prostrate, the highest voltage, all must lean on volume unshakable in one's determination The layer insulation of sheet is intercepted, just in case layer insulation produces connection not, will produce a large amount of Vortex flow, makes transformer core heating damage itself.So eddy current problems is that rewinding material structure must The great restraining factors that must solve.

The present invention is for overcoming the solution of vortex flow, it is simply that open in the appearance unshakable in one's determination rolled into Axial groove, axial groove reaches insulation mandrel always, is equivalent to cut off the wire turn all connected, Induced voltage just cannot be connected to accumulate and be increased, thus eliminates the voltage source producing vortex flow.

For more powerful large-scale iron core, it is also possible to by different radial positions, output a plurality of axially Groove, axial groove is that divergent shape is uniformly distributed, and makes every section of induced voltage be less than 10V, even lower, The probability producing vortex flow will be the least, at most as the level of eddy current in stalloy.Axial groove with Magnetic current is equidirectional, does not the most affect the flowing of magnetic current.Owing to slotting the area of core section lost also Not quite, can ignore.

Fig. 8 is the rewinding material schematic diagram manufactured.Its profile is divergent shape, is similar to seletron Flos Chrysanthemi sheet used by, the size of certain rewinding material is more much bigger than Flos Chrysanthemi sheet, and shape is cylinder Shape, this is difference.Generally speaking, it is characterized in that of rewinding material of the present invention, rewinding material has one Bar or several axial grooves, to eliminate vortex flow unshakable in one's determination.

In order to strengthen the heat radiation of high-power transformer, it is possible to insulation tank is retained the steam as ventilation and heat Stream or deep fat circulation road.It is characterized in that in the minds of transformer fe, having one or several to be made up of axial dielectric groove Heat dissipation channel.

The Second Problem that should be noted that in the present invention, is that the magnetic current orientation about oriented silicon steel band is asked Topic.Existing finished silicon steel band is mainly for the manufacture of ring-shaped transformer, c-type transformator and R type transformator Deng needs, so magnetic current orientation with exhibition band direction consistent, can along exhibition band direction employing all pointss roll up Around, as shown in Figure 9.

Fig. 9 is silicon strip magnetic current orientation and cutting wires relation schematic diagram in existing goods coiled strip.

Iron core in the present invention, for ensureing that magnetic current flows by axial in iron core, as used existing business Product orientation silicon steel winding, should use and horizontal cut into segment, then splicing growth section winding, in splicing Time, before and after's section material strip can be made to make electrical isolation and to connect, the most not allow before and after's metal tape contact, quite In increasing insulation between material strip, then be conducive to eliminating vortex flow, in this case, if also need to Fluting insulation, then can be determined on a case-by-case basis.

Or using along the silicon strip perpendicular with exhibition band direction, this most equally takes all pointss system Feeding band, it is not necessary to splicing, but the iron core so made must open insulation tank.

Figure 10 is to use the relation between the sawing sheet direction of sheet material and magnetic current orientation, it is seen then that cutting wires Total and magnetic current direction keeps vertical relation.

Above-mentioned three-phase transformer is core type, below for zero clearance magnetic circuit shell-type three-phase transformer structure Explain.

So-called shell-type three-phase transformer in the present invention, it is simply that one is similar to traditional three-phase and five-pole The transformator of formula structure.

As its name suggests, the so-called shell-type three-phase transformer in the present invention, must be and tradition pentastyle Transformator has the zero clearance magnetic structure of different configuration and manufacture method.

Figure 11 is the construction profile schematic diagram of the zero clearance magnetic circuit shell-type three-phase transformer of the present invention.

In shell type structure, first having to make an iron yoke frame, this iron yoke frame can be become by stalloy stamping-out Punching be formed by stacking, such structure, magnetic circuit gap is minimum, and magnetic resistance is the most less, after closed assembly, Faying face in frame makees polish.The transformator constituted has from solidity, and this structure must be adopted Install with hot cover process, guarantee zero clearance magnetic circuit, and the structure of spill circular groove cannot be used, But such a shell type transformer iron yoke must use non-oriented silicon steel sheet stamping-out, this is a shortcoming.

For the transformator of relatively high power, iron yoke frame size is too big, is not easy to use seamless iron yoke Frame, at this moment can use grain-oriented Si steel sheet to be cut into wide bar shaped cut-parts and fold and form.Cut-parts interlock Closed assembly, may be used without mitered cut-parts at seam, although mitered cut-parts ferromagnetic material utilization rate is Reduce, but to reducing seam magnetic resistance, particularly reduce the magnetic field turning loss in oriented electrical steel. It is all effectively.

Chinese invention patent application seen from the detailed description of zero clearance magnetic circuit shell type transformer " 201310203975.X zero clearance and few gap magnetic circuit transformator ".

Owing to present invention employs zero clearance magnetic circuit and non-laminated iron core, reduce magnetic loss, improve Transformer efficiency.Such conservation measures is not accomplished in traditional laminated type structure transformer, Meanwhile, structure design also significantly reduces the difficulty of lamination, and the requirement to stacking technique precision, Be conducive to saving time cost.

Claims (12)

1. the three-phase energy-saving transformer being mainly made up of winding, iron core and yoke three parts, It is characterized in that, iron core is non-laminated type circular cross-section structure；Iron yoke is silicon steel sheet stack mould assembly square-section Structure；Zero clearance magnetic structure is constituted between iron core and iron yoke.

Three-phase energy-saving transformer the most according to claim 1, is characterized in that, non-in magnetic circuit Laminated type (1) unshakable in one's determination is to be wound by soft iron or filled by magnetic powder to form；Unshakable in one's determination and iron yoke is independent Split parts；Winding (2) and (1) unshakable in one's determination overall middle independent part being also integrated before total assembling Part；Having the faying face through polish between (1) unshakable in one's determination and iron yoke (3), faying face is that zero tolerance is joined Close.

3. according to the manufacture method of the three-phase energy-saving transformer described in claim 1 or claim 2, its Feature is, replaces the common closed assembly of magnetic circuit with unshakable in one's determination and iron yoke difference closed assembly；Tie with unshakable in one's determination and iron yoke The polish in conjunction face replaces the precision positioning closed assembly of magnetic circuit.

The manufacture method of three-phase energy-saving transformer the most according to claim 3, is characterized in that, manufactures Journey include winding unshakable in one's determination or filling, winding manufacture, iron yoke manufacture, faying face polish, general assembly, its Its adnexa is installed.

The manufacture method of three-phase energy-saving transformer the most according to claim 3, is characterized in that, iron yoke is adopted Use vertical closed assembly.

The manufacture method of three-phase energy-saving transformer the most according to claim 3, is characterized in that, in assembling Using strong adherence firming agent, or add magnetic conductivity microgranule again in firming agent, magnetic conduction microgranule may It is inorganic magnetic conductor, organic magnetic conductor, or nanometer magnetic conductor.

7., according to the three-phase energy-saving transformer described in claim 1 or claim 2, it is characterized in that, on The faying face structure of three band spill circular grooves it is respectively arranged with on lower yoke.

8., according to the three-phase energy-saving transformer described in claim 1 or claim 2, it is characterized in that, Iron core is convoluted.

9. according to the three-phase energy-saving transformer described in claim 1 or claim 2, it is characterized in that, magnetic Property material is ferrum Si system alloy, ferrum aluminum series alloy, ferrum silicon aluminum series alloy, nickel iron-based alloy, ferrum cobalt system Alloy, carbonyl iron, soft magnetic ferrite, amorphous soft magnetic alloy, super-microcrystalline soft magnetic alloy, iron-based are non- Peritectic alloy, amorphous nano-crystalline alloy soft magnetic composite.

10. according to the three-phase energy-saving transformer described in claim 1 or claim 8, it is characterized in that, at volume Iron core has one or several axial dielectric groove, to eliminate vortex flow unshakable in one's determination.

11. three-phase energy-saving transformers according to claim 10, is characterized in that having in the minds of transformer fe One or several heat dissipation channel being made up of axial dielectric groove.

12., according to the three-phase energy-saving transformer described in claim 1 or claim 8, is characterized in that, Transformator can be heart type structure, it is also possible to be shell type structure.