A kind of elliptical self-saturated reactor core and its manufacturing equipment and manufacturing method

Abstract

The present invention discloses an elliptical self-saturating reactor core, a manufacturing device and a manufacturing method. The elliptical self-saturating reactor core is formed by winding silicon steel sheet coils. The shape of the central through hole of the elliptical self-saturating reactor core is the same as the overall shape of the elliptical self-saturating reactor core, which is elliptical. The ends of the silicon steel sheet coils on the inner and outer sides of the elliptical self-saturating reactor core are provided with welding spots for fixation. The present invention adopts a elliptical core structure to replace the traditional circular core, which not only reduces the amount of silicon steel sheets used and reduces the material cost, but also is superior to the traditional structure in terms of strength, volume, weight, loss and noise. The core has a smaller cross-section, and the loss during operation is proportional to the weight, the loss is lower, and the noise is greatly reduced after casting.

Description

Technical Field

[0001] The present invention relates to the technical field of self-saturated reactor cores, and in particular to an elliptical self-saturated reactor core, a manufacturing device and a manufacturing method. Background Art

[0002] As a key component of the self-saturated reactor, the structure and performance of the self-saturated reactor core have an important impact on the overall performance of the reactor. The existing self-saturated reactor cores mostly adopt a circular ring structure, such as Figure 5 As shown, the material is mainly cold-rolled silicon steel sheets with a thickness of 0.27mm or 0.3mm, and is manufactured using a traditional winding process. Although this traditional toroidal core structure can meet the basic operating requirements of self-saturated reactors to a certain extent, it also has many limitations.

[0003] In terms of material usage, traditional toroidal cores use a relatively high amount of silicon steel sheets to achieve the required performance, resulting in high material costs and hindering economic optimization of the equipment. From a structural performance perspective, their strength is average, and they may not provide sufficient mechanical support and stability under certain operating conditions or installation requirements. Furthermore, due to their inherent shape and size, the core is relatively large and heavy, which not only increases the difficulty of transporting and installing the equipment but also limits the use of self-saturated reactors in applications with strict space and weight constraints.

[0004] In terms of operating performance, the losses and noise levels of traditional toroidal cores need to be further reduced. The operating losses of a core are proportional to its weight, and traditional toroidal structures still have room for improvement in loss control. Furthermore, noise levels also affect the environmental friendliness of self-saturated reactors. In noise-sensitive locations, such as substations near residential areas, the noise performance of traditional cores may be limited.

[0005] In summary, there is a need for improvement in the existing toroidal core of self-saturated reactors in terms of material utilization, structural performance, and operating performance. The market urgently needs a more optimized core structure to overcome the above-mentioned shortcomings of traditional toroidal cores and improve the overall performance and application adaptability of self-saturated reactors. Summary of the Invention

[0006] In view of the deficiencies in the prior art, the present invention provides a self-saturating reactor core having a quasi-elliptical shape, and a manufacturing device and a manufacturing method thereof, which aim to solve the problems in the background technology.

[0007] To achieve the above-mentioned object, the present invention provides the following technical solution: an elliptical self-saturating reactor core, comprising: the elliptical self-saturating reactor core is wound from a silicon steel sheet coil; the shape of the central through hole of the elliptical self-saturating reactor core is the same as the overall shape of the elliptical self-saturating reactor core, which is a elliptical shape; and welding points for fixing are provided on the ends of the silicon steel sheet coil on the inner and outer sides of the elliptical self-saturating reactor core.

[0008] A device for manufacturing an elliptical self-saturated reactor core, comprising:

[0009] Winding machine;

[0010] A material unwinding platform is provided on one side of the winding machine and is used for placing silicon steel sheet coils;

[0011] An inner core mold is provided on top of the winding machine and is used to cooperate with the winding machine to wind the silicon steel sheet into a self-saturated reactor core in a substantially elliptical shape;

[0012] A fixing device, which is provided on the winding machine and is used to fix the core inner mold;

[0013] The clamping device is arranged on the winding machine and is used to clamp the silicon steel sheet when it is coiled.

[0014] Furthermore, the core inner mold includes a square mold body, and two vertically arranged round steels are respectively provided on both sides of the square mold body; two vertically arranged fixing holes are axially symmetrically provided on the square mold body and pass through the square mold body; chamfers are provided on the four vertical sides of the square mold body.

[0015] Furthermore, the round steels on both sides of the square mold body are arranged opposite to each other.

[0016] A method for manufacturing a quasi-elliptical self-saturating reactor core comprises the following steps:

[0017] Step S1: hoisting the silicon steel sheet coil and placing it on the unloading platform;

[0018] Step S2: inserting the core inner mold into the fixing device on the top of the winding machine through the fixing hole, and fastening the core inner mold through the fixing device;

[0019] Step S3: unwinding the silicon steel sheet coil and adhering the outer end of the silicon steel sheet coil to the core inner mold with a non-stick tape;

[0020] Step S4: starting the winding machine to wind the silicon steel sheet onto the core inner mold;

[0021] Step S5: When the thickness of the silicon steel sheet coil on the core inner mold reaches the required value, the silicon steel sheet coil is cut and then fixed at the outer end of the silicon steel sheet coil using a resistance welding machine;

[0022] Step S6: Loosen the fixing device, remove the core inner mold and the silicon steel sheet coil wound on the core inner mold, and place them into an annealing furnace for annealing;

[0023] Step S7: After annealing and cooling, the core inner mold is removed, and the inner end of the wound silicon steel sheet coil is fixed by electric welding using a resistance welding machine;

[0024] Step S8: placing the wound silicon steel sheet coil into a vacuum tank for evacuation, and then performing pressure dipping; after the dipping is completed, taking it out and drying it to complete the production of the elliptical self-saturated reactor core.

[0025] Furthermore, when the silicon steel sheet coil is wound, the wound silicon steel sheet coil is compressed by a compression device, and the winding speed and tension are controlled during the winding process.

[0026] Furthermore, when the silicon steel sheet coil on the core inner mold is wound to a preset thickness, the clamping device is released and the pressure is adjusted before continuing the winding.

[0027] Furthermore, the annealing temperature is controlled at 800°C.

[0028] Compared with the existing technology, the present invention has the following beneficial effects:

[0029] (1) The present invention adopts an elliptical core structure to replace the traditional annular core, which not only reduces the amount of silicon steel sheets used and reduces material costs, but also outperforms the traditional structure in terms of strength, volume, weight, loss and noise. The core cross-section is smaller, the loss during operation is proportional to the weight, the loss is lower, and the noise is greatly reduced after casting.

[0030] (2) The inner mold of the core of the present invention is simple to manufacture and low in cost. After winding, the shape is well controlled and there is no looseness between layers. The clamping device can ensure that the core is tight during the winding process. The multi-pass electric welding of the resistance welding machine can prevent the silicon steel sheets from spreading. The vacuum pressure dipping paint can make the core layers stick together as a whole, further improving the performance.

[0031] (3) The present invention has significant advantages in terms of material utilization, manufacturing process and final performance, and realizes the production of high-quality and high-performance cores. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a schematic diagram of the structure of the elliptical self-saturated reactor core of the present invention.

[0033] Figure 2This is a structural schematic diagram of the equipment for manufacturing the elliptical self-saturated reactor core of the present invention.

[0034] Figure 3 This is a connection diagram of the elliptical self-saturated reactor core and the core inner mold of the present invention.

[0035] Figure 4 It is a schematic diagram of the core inner mold structure of the present invention.

[0036] Figure 5 Schematic diagram of the existing self-saturated reactor core structure.

[0037] In the figure, 1. Clamping device; 2. Fixing device; 3. Iron core inner mold; 31. Square mold body; 32. Round steel; 33. Fixing hole; 4. Oval-shaped self-saturated reactor core; 5. Winding machine; 6. Unwinding table; 7. Silicon steel sheet coil; 8. Welding point. DETAILED DESCRIPTION

[0038] like Figure 1 As shown, the present invention provides a technical solution: an elliptical self-saturated reactor core, comprising: the elliptical self-saturated reactor core 4 is wound by a silicon steel sheet coil 7; the shape of the central through hole of the elliptical self-saturated reactor core 4 is the same as the overall shape of the elliptical self-saturated reactor core 4, which is a elliptical shape; and welding points 8 for fixing are provided on the ends of the silicon steel sheet coil 7 on the inner and outer sides of the elliptical self-saturated reactor core 4.

[0039] like Figure 2-Figure 4 As shown, a device for manufacturing an elliptical self-saturated reactor core includes:

[0040] Winding machine 5.

[0041] The unloading platform 6 is arranged on one side of the winding machine 5 and is used to place the silicon steel sheet coil 7.

[0042] The core inner mold 3 is arranged on the top of the winding machine 5 and is used to cooperate with the winding machine 5 to wind the silicon steel sheet coil 7 into a self-saturated reactor core 4 with a similar elliptical shape.

[0043] The fixing device 2 is provided on the winding machine 5 and is used to fix the core inner mold 3 .

[0044] The pressing device 1 is provided on the winding machine 5 and is used to press the silicon steel sheet coil 7 when it is wound.

[0045] Among them, the core inner mold 3 includes a square mold body 31, and two vertically arranged round steels 32 are respectively provided on both sides of the square mold body 31; two vertically arranged fixing holes 33 are axially symmetrically provided on the square mold body 31 and pass through the square mold body 31; chamfers are provided on the four vertical sides of the square mold body 31.

[0046] The round steel bars 32 on both sides of the square mold body 31 are arranged opposite to each other.

[0047] In this embodiment, the length of the square mold body 31 can be set to 170 mm and the width can be set to 70 mm; the chamfer radius of the four vertical sides of the square mold body 31 can be set to 6 mm; the distance between the centers of the two fixing holes 33 of the square mold body 31 can be set to 100 mm; and the distance between the centers of the two vertically arranged round steels 32 on any side of the square mold body 31 can be set to 50 mm.

[0048] A method for manufacturing a quasi-elliptical self-saturating reactor core comprises the following steps:

[0049] Step S1: hoisting and placing the silicon steel sheet coil 7 on the unloading platform 6 .

[0050] Step S2: insert the core inner mold 3 into the fixing device 2 on the top of the winding machine 5 through the fixing hole 33 , and fasten the core inner mold 3 through the fixing device 2 .

[0051] Step S3: unpack the silicon steel sheet coil 7 and stick the outer end of the silicon steel sheet coil 7 to the core inner mold 3 with a non-stick tape.

[0052] Step S4: Start the winding machine 5 to wind the silicon steel sheet coil 7 onto the core inner mold 3.

[0053] Step S5: When the winding thickness of the silicon steel sheet coil 7 on the core inner mold 3 reaches the required value, the silicon steel sheet coil 7 is cut and then fixed by electric welding 8 at 10 mm from the outer end of the silicon steel sheet coil 7 using a resistance welding machine.

[0054] Step S6: Loosen the fixing device 2, remove the core inner mold 3 and the silicon steel sheet coil 7 wound on the core inner mold 3, and put them into an annealing furnace for annealing. The annealing temperature is controlled at 800°C.

[0055] Step S7: After annealing and cooling, the core inner mold 3 is removed, and the inner end of the wound silicon steel sheet coil 7 is fixed by electric welding points 8 using a resistance welding machine.

[0056] Step S8: placing the wound silicon steel sheet coil 7 into a vacuum tank for evacuation, and then pressure-dipping with varnish (resin); after dipping, taking it out and drying it, the elliptical self-saturated reactor core 4 is manufactured.

[0057] When the silicon steel sheet coil 7 is wound, the wound silicon steel sheet coil 7 is compressed by the compression device 1 , and the winding speed and tension are controlled during the winding process.

[0058] When the silicon steel sheet coil 7 on the core inner mold 3 is wound to a certain thickness (usually 10-20 mm), the pressing device 1 is released and the pressure is adjusted before continuing the winding.

[0059] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A self-saturated reactor core of elliptical shape, characterized in that: include: The quasi-elliptical self-saturating reactor core is formed by winding silicon steel sheet coils; the shape of the central through hole of the quasi-elliptical self-saturating reactor core is the same as the overall shape of the quasi-elliptical self-saturating reactor core, which is a quasi-elliptical shape; welding points for fixing are provided on the ends of the silicon steel sheet coils on the inner and outer sides of the quasi-elliptical self-saturating reactor core; The elliptical self-saturated reactor core is formed by winding silicon steel sheet coils on an inner core mold; the inner core mold includes a square mold body, and two vertically arranged round steels are respectively provided on both sides of the square mold body; two vertically arranged fixing holes are axially symmetrically provided on the square mold body and pass through the square mold body; the four vertical sides of the square mold body are provided with chamfers; the round steels on both sides of the square mold body are arranged opposite to each other; The length of the square mold body is 170mm and the width is 70mm; the chamfer radius of the four vertical sides of the square mold body is 6mm; the distance between the centers of the two fixing holes of the square mold body is 100mm; the distance between the centers of the two vertically arranged round steels on any side of the square mold body is 50mm.

2. A device for manufacturing a quasi-elliptical self-saturating reactor core, used for manufacturing the quasi-elliptical self-saturating reactor core according to claim 1, characterized in that: include: Winding machine; A material unwinding platform is provided on one side of the winding machine and is used for placing silicon steel sheet coils; An inner core mold is provided on top of the winding machine and is used to cooperate with the winding machine to wind the silicon steel sheet into a self-saturated reactor core in a substantially elliptical shape; A fixing device, which is provided on the winding machine and is used to fix the core inner mold; A pressing device is provided on the winding machine and is used to press the silicon steel sheet when it is coiled; The core inner mold includes a square mold body, two vertically arranged round steel bars are respectively provided on both sides of the square mold body; two vertically arranged fixing holes are axially symmetrically provided on the square mold body and pass through the square mold body; four vertical sides of the square mold body are provided with chamfers; the round steel bars on both sides of the square mold body are arranged opposite to each other; The length of the square mold body is 170mm and the width is 70mm; the chamfer radius of the four vertical sides of the square mold body is 6mm; the distance between the centers of the two fixing holes of the square mold body is 100mm; the distance between the centers of the two vertically arranged round steels on any side of the square mold body is 50mm.

3. A method for manufacturing a quasi-elliptical self-saturating reactor core, for manufacturing the quasi-elliptical self-saturating reactor core according to claim 1 using the manufacturing equipment according to claim 2, characterized in that: The steps include: Step S1: hoisting the silicon steel sheet coil and placing it on the unloading platform; Step S2: inserting the core inner mold into the fixing device on the top of the winding machine through the fixing hole, and fastening the core inner mold through the fixing device; Step S3: unwinding the silicon steel sheet coil and adhering the outer end of the silicon steel sheet coil to the core inner mold with a non-stick tape; Step S4: starting the winding machine to wind the silicon steel sheet onto the core inner mold; Step S5: When the thickness of the silicon steel sheet coil on the core inner mold reaches the required value, the silicon steel sheet coil is cut and then fixed at the outer end of the silicon steel sheet coil using a resistance welding machine; Step S6: Loosen the fixing device, remove the core inner mold and the silicon steel sheet coil wound on the core inner mold, and place them into an annealing furnace for annealing; Step S7: After annealing and cooling, the core inner mold is removed, and the inner end of the wound silicon steel sheet coil is fixed by electric welding using a resistance welding machine; Step S8: placing the wound silicon steel sheet coil into a vacuum tank for evacuation, and then performing pressure dipping; after the dipping is completed, taking it out and drying it to complete the production of the elliptical self-saturated reactor core.

4. The method for manufacturing a self-saturated elliptical reactor core according to claim 3, wherein: When winding the silicon steel sheet coil, the wound silicon steel sheet coil is compressed by the compression device, and the winding speed and tension are controlled during the winding process.

5. The method for manufacturing a self-saturated elliptical reactor core according to claim 4, characterized in that: When the silicon steel sheet coil on the core inner mold is wound to the preset thickness, the clamping device is released and the pressure is adjusted before continuing the winding.

6. The method for manufacturing a self-saturated elliptical reactor core according to claim 3, wherein: The annealing temperature is controlled at 800°C.

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