Three-dimensional wound core manufacturing method and three-dimensional wound core

Abstract

According to the manufacturing method of the three-dimensional wound iron core and the three-dimensional wound iron core, the silicon steel material and the amorphous material for preparing the iron core are firstly obtained, then the two materials are cut to obtain the silicon steel strip-shaped material and the amorphous strip-shaped material, then the silicon steel iron core frame with the embedded structure is wound by the silicon steel strip-shaped material, and the silicon steel iron core frame with the embedded structure is manufactured. And the amorphous iron core frame is wound by the amorphous strip-shaped material, and the frame edge width of the amorphous iron core frame is matched with the width of the embedded structure. And then, the two iron core frames are subjected to annealing treatment, the annealed silicon steel iron core frame and amorphous iron core frame are spliced to obtain an iron core single frame, then the iron core single frame is spliced and cured, and the three-dimensional wound iron core is obtained. The characteristics of the silicon steel material and the amorphous material are combined, the advantages of the silicon steel material and the amorphous material are complementary, the three-dimensional wound core has good mechanical performance and no-load performance at the same time, and the overall performance of the transformer is improved.

Description

Technical Field

[0001] The embodiments of the present application relate to, but are not limited to, the technical field of transformer component production, and in particular to a method for manufacturing a three-dimensional wound core and a three-dimensional wound core. Background Art

[0002] Currently, the core materials used in transformers are primarily silicon steel and amorphous alloys. Silicon steel, with its excellent mechanical properties, exhibits low vibration and noise during transformer operation. However, its poor no-load performance results in significant energy losses in the transformer during no-load operation, which undoubtedly increases the operating costs of the power system. Amorphous alloys, on the other hand, offer excellent no-load performance, reducing no-load losses and effectively improving energy efficiency. However, their poor mechanical properties result in high vibration and noise levels during transformer operation, impacting not only the stability and service life of the equipment itself but also potentially causing noise pollution to the surrounding environment. Summary of the Invention

[0003] The following is a summary of the subject matter described in detail herein. This summary is not intended to limit the scope of the claims.

[0004] The embodiments of the present application provide a method for manufacturing a three-dimensional wound core and a three-dimensional wound core. By combining the characteristics of silicon steel material and amorphous material, the advantages of the two are complemented, so that the three-dimensional wound core has both good mechanical properties and no-load performance, thereby improving the overall performance of the transformer.

[0005] In a first aspect, an embodiment of the present application provides a method for manufacturing a three-dimensional wound core, comprising: obtaining silicon steel material and amorphous material for preparing the core; cutting the silicon steel material and the amorphous material separately to obtain silicon steel strip material and amorphous strip material; using the silicon steel strip material to wind a silicon steel core frame with an embedded structure, and using the amorphous strip material to wind an amorphous core frame, wherein the frame edge width of the amorphous core frame matches the width of the embedded structure; annealing the silicon steel core frame and the amorphous core frame separately, and splicing the annealed silicon steel core frame and the amorphous core frame to obtain a single core frame; assembling and curing the single core frames to obtain a three-dimensional wound core.

[0006] In combination with the first aspect, in an embodiment of the present application, the annealing treatment of the silicon steel core frame and the amorphous iron core frame respectively includes: sending the amorphous iron core frame into a first annealing furnace for annealing treatment, magnetizing during the annealing process, and the annealing temperature range of the first annealing furnace is 300°C to 500°C; sending the silicon steel core frame into a second annealing furnace for annealing treatment, and the annealing temperature range of the second annealing furnace is 700°C to 900°C.

[0007] In combination with the first aspect, in an embodiment of the present application, after annealing the silicon steel core frame and the amorphous iron core frame, the method further includes: wrapping or curing the amorphous iron core frame.

[0008] In combination with the first aspect, in an embodiment of the present application, the step of curing the amorphous core frame includes: applying core paint or core glue on the surface of the amorphous core frame.

[0009] In combination with the first aspect, in an embodiment of the present application, splicing the annealed silicon steel core frame and the amorphous iron core frame includes: performing insulation treatment between the silicon steel core frame and the amorphous iron core frame and then assembling them.

[0010] In combination with the first aspect, in an embodiment of the present application, the step of assembling the core single frames includes: performing insulation treatment on the core single frames and then assembling them.

[0011] On the second aspect, an embodiment of the present application provides a three-dimensional wound core, which applies the above-mentioned three-dimensional wound core manufacturing method. The three-dimensional wound core includes a plurality of core single frames spliced ​​together, and the core single frames include a silicon steel core frame and an amorphous core frame. The silicon steel core frame is provided with an embedded structure, and the frame edge width of the amorphous core frame matches the width of the embedded structure. The amorphous core frame is embedded with the silicon steel core frame through the embedded structure.

[0012] The method for making a three-dimensional wound core provided in an embodiment of the present application comprises the following steps: first, obtaining silicon steel material and amorphous material for preparing the core; then, cutting the silicon steel material and amorphous material respectively to obtain silicon steel strip material and amorphous strip material; then, using the silicon steel strip material to wind a silicon steel core frame with an embedded structure, and using the amorphous strip material to wind an amorphous core frame, wherein the frame edge width of the amorphous core frame matches the width of the embedded structure. Subsequently, the silicon steel core frame and the amorphous core frame are annealed respectively, and the annealed silicon steel core frame and the amorphous core frame are spliced ​​to obtain a single core frame, and then the single core frame is assembled and cured to obtain a three-dimensional wound core. This embodiment effectively combines the characteristics of the two materials by using silicon steel material and amorphous material to prepare a three-dimensional wound core, avoids the shortcomings of the two materials, and allows the advantages of the two materials to complement each other, so that the three-dimensional wound core has both good mechanical properties and no-load performance, thereby improving the overall performance of the transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a flow chart of a method for manufacturing a three-dimensional wound core provided by one embodiment of the present application;

[0014] Figure 2 This is an overall structural diagram of a three-dimensional wound core provided by an embodiment of the present application;

[0015] Figure 3 This is a diagram of the exploded structure of a single core frame provided in one embodiment of the present application. DETAILED DESCRIPTION

[0016] In order to make the purpose, technical solutions and advantages of this application more clear, the following further describes this application in detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain this application and are not intended to limit this application.

[0017] It should be noted that although a logical order is shown in the flowchart, in some cases, the steps shown or described may be performed in an order different from that in the flowchart. The terms "first" and "second" in the specification, claims, and the above-mentioned figures are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be noted that the structures, proportions, sizes, etc. depicted in the drawings of this specification are only used to match the content disclosed in the specification for people familiar with the technology to understand and read, and are not used to limit the conditions under which the present invention can be implemented. Therefore, they have no technical significance. Any modification of the structure, change in the proportional relationship, or adjustment of the size should still fall within the scope of the technical content disclosed in the present invention without affecting the efficacy and purpose of the present invention. At the same time, the terms such as "upper", "lower", "left", "right", "middle", and "one" used in this specification are only for the convenience of description and are not used to limit the scope of the present invention. Changes or adjustments in their relative relationships should also be considered as the scope of the present invention without substantially changing the technical content.

[0018] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this application pertains. The terms used herein are for the purpose of describing the embodiments of this application only and are not intended to limit this application.

[0019] With the development of the power grid, energy conservation requirements are becoming increasingly stringent, and the performance requirements for transformers are also constantly increasing. Currently, the core materials of transformer products are mainly silicon steel sheets and amorphous alloys. Silicon steel sheets, due to their excellent mechanical properties, exhibit low vibration and low noise during transformer operation. However, their poor no-load performance leads to significant energy losses in the transformer during no-load operation, which undoubtedly increases the operating costs of the power system. Amorphous alloy materials have excellent no-load performance, which can reduce the no-load losses of transformers and effectively improve energy efficiency. However, their poor mechanical properties lead to high vibration and noise during transformer operation, which not only affects the stability and service life of the equipment itself, but also may cause noise pollution to the surrounding environment.

[0020] In view of this, an embodiment of the present application provides a method for manufacturing a three-dimensional wound core and a three-dimensional wound core. In this method, first, silicon steel material and amorphous material for preparing the core are obtained; then, the silicon steel material and the amorphous material are cut separately to obtain silicon steel strip material and amorphous strip material; then, a silicon steel core frame with an embedded structure is wound with the silicon steel strip material, and an amorphous core frame is wound with the amorphous strip material, wherein the frame edge width of the amorphous core frame matches the width of the embedded structure. Subsequently, the silicon steel core frame and the amorphous core frame are annealed separately, and the annealed silicon steel core frame and the amorphous core frame are spliced ​​to obtain a single core frame, and then the single core frame is assembled and cured to obtain a three-dimensional wound core. This embodiment effectively combines the characteristics of the two materials by using silicon steel material and amorphous material to prepare a three-dimensional wound core, so that the three-dimensional wound core has both good mechanical properties and no-load performance, thereby improving the overall performance of the transformer.

[0021] The embodiments of the present application are further described below with reference to the accompanying drawings.

[0022] See also Figure 1 , Figure 1 This is a flow chart of a method for manufacturing a three-dimensional wound core according to an embodiment of the present application. The process may include but is not limited to steps 110 to 150.

[0023] Step 110: Obtain silicon steel material and amorphous material for preparing an iron core;

[0024] Step 120: Cutting the silicon steel material and the amorphous material respectively to obtain silicon steel strip material and amorphous strip material;

[0025] Step 130: Using silicon steel strip material to wind a silicon steel core frame with an embedded structure, and using amorphous strip material to wind an amorphous core frame, wherein the frame side width of the amorphous core frame matches the width of the embedded structure;

[0026] Step 140: annealing the silicon steel core frame and the amorphous iron core frame respectively, and splicing the annealed silicon steel core frame and the amorphous iron core frame to obtain a single core frame;

[0027] Step 150: Assemble and solidify the core single frames to obtain a three-dimensional wound core.

[0028] In one embodiment, the silicon steel material is an iron-based alloy containing silicon, which has good magnetic permeability and can effectively reduce the hysteresis loss of the transformer. The amorphous material is a metal material with disordered internal atomic arrangement, which has excellent soft magnetic properties, especially in reducing no-load losses. For example, in the common production of power transformers, high-permeability oriented silicon steel sheets can be used as silicon steel materials, and iron-based amorphous alloy strips can be used as amorphous materials. The obtained silicon steel materials and amorphous materials must meet the corresponding quality standards to ensure that the performance of the subsequently produced core meets the requirements.

[0029] In one embodiment, slitting is the process of cutting large pieces of raw materials into specific sizes and shapes. For silicon steel materials and amorphous materials, the purpose of slitting is to process them into a strip shape suitable for winding the iron core. Silicon steel materials are usually cut according to the pre-designed width and length using shearing equipment to obtain silicon steel strip materials. Due to the brittle texture of amorphous materials, high-precision cutting equipment is usually used for slitting to avoid cracks or damage to the material during the cutting process, thereby obtaining amorphous strip materials. For example, in a transformer production workshop, a high-precision CNC shearing machine is used to cut silicon steel sheets, which can accurately control the width tolerance of the silicon steel strip material within ±0.05mm; for amorphous materials, high-power laser cutting equipment is used to improve cutting efficiency while ensuring cutting quality.

[0030] In one embodiment, winding is the process of wrapping a strip of material around a specific mold or mandrel to form the desired core frame shape. During the winding process of the silicon steel core frame, an embedded structure is constructed using special winding equipment and molds. This embedded structure can be designed in the form of grooves or protrusions to facilitate subsequent splicing with the amorphous core frame. The amorphous core frame also uses a winding process, winding amorphous strip material on a dedicated winding machine. The frame edge width of the amorphous core frame must be strictly controlled to precisely match the width of the embedded structure on the silicon steel core frame to ensure a tight splicing. For example, in actual production, by adjusting the parameters of the winding machine, the width of the embedded structure of the silicon steel core frame is controlled to 5 mm, while the frame edge width of the amorphous core frame is adjusted to slightly less than 5 mm. It is important to note that a certain margin should be reserved when splicing the silicon steel core frame and the amorphous core frame to leave space for subsequent insulation treatment, thereby ensuring the accuracy and stability of the subsequent splicing.

[0031] In one embodiment, annealing is a heat treatment process used to eliminate the internal stress generated in the material during processing and improve the magnetic and mechanical properties of the material. When annealing the silicon steel core frame and the amorphous iron core frame, different annealing temperatures and times need to be set according to the material properties. The silicon steel core frame is generally annealed at a higher temperature to optimize its magnetic permeability; the annealing temperature of the amorphous iron core frame is relatively low, mainly to restore the stability of its amorphous structure. The annealed silicon steel core frame and the amorphous iron core frame can be spliced ​​through the embedded structure to form a complete single core frame.

[0032] In one embodiment, in step 140, the silicon steel core frame and the amorphous iron core frame are first annealed separately. The specific process is as follows: the amorphous iron core frame is sent to a first annealing furnace and annealed within an annealing temperature range of 300°C to 500°C, and magnetization is performed during the annealing process. For example, for the amorphous iron core frame, it can be kept in an annealing furnace at 400°C for 1 hour and then naturally cooled. The silicon steel core frame is sent to a second annealing furnace, and its annealing temperature range is 700°C to 900°C. For example, for the silicon steel core frame, it can be placed in a high-temperature annealing furnace, kept at a temperature of 800°C for 2 hours, and then cooled with the furnace. After annealing is completed, splicing is performed, and the frame edge of the amorphous iron core frame is accurately embedded in the embedded structure of the silicon steel core frame, and fixed with a special clamp to ensure that the splicing is tight and without gaps.

[0033] In one embodiment, in the core preparation process, after the annealing treatment of the silicon steel core frame and the amorphous core frame is completed, the amorphous core frame can be further wrapped or cured. It is understandable that the inherent characteristics of amorphous materials determine that they are brittle and have poor mechanical properties. Even after annealing to optimize the magnetic properties, they are very likely to be damaged by external forces during subsequent operations such as assembly with the silicon steel core frame. Through protective measures such as wrapping or curing treatment, the mechanical strength and structural stability of the amorphous core frame can be enhanced, effectively avoiding the risk of damage that may occur during the assembly process. Among them, wrapping is to use a material with suitable strength and good flexibility to wrap the amorphous core frame. For example, in an actual production scenario, for an amorphous core frame of a distribution transformer with a rated capacity of 100kVA, a polyester film tape with a width of 20mm can be selected as the wrapping material. A tight and uniform spiral winding method is used to wrap multiple layers (such as 5 layers). During assembly with the silicon steel core frame, the amorphous core frame effectively absorbs various external forces, significantly reducing the likelihood of breakage or deformation due to stress, thereby safeguarding its structural integrity. Curing involves applying specific materials to the surface of the amorphous core frame, causing them to undergo physical or chemical transformations under specific conditions, thereby forming a hard and durable outer shell, significantly enhancing the mechanical properties of the amorphous core frame. Curing methods primarily include the application of core paint or core glue. Core paint is typically composed of a judicious combination of resin, solvent, and various functional additives. During the application of core paint to the amorphous core frame, as the solvent gradually evaporates, the resin slowly and evenly cures on the surface, ultimately forming a dense, hard paint film. This cured paint film not only effectively enhances the mechanical strength of the amorphous core frame, enabling it to withstand greater external forces, but also significantly improves its insulation properties, effectively eliminating potential leakage hazards during transformer operation. Core glue is an adhesive with extremely high bond strength. It can firmly bond the various parts of the amorphous core frame together, making it a tight and stable whole, thereby effectively enhancing the overall mechanical stability of the amorphous core frame. After the curing process, the amorphous core frame becomes extremely structurally stable. Even in complex and harsh operating environments, such as the vibration and impact conditions frequently encountered in power systems, it can always maintain its structural integrity and is not prone to loosening or deformation.

[0034] Understandably, silicon steel and amorphous alloys differ in their electromagnetic properties. Silicon steel has higher magnetic permeability and lower hysteresis losses. While amorphous alloys offer excellent no-load performance, direct contact between the two can generate currents due to their different electromagnetic properties, potentially causing electromagnetic interference and impacting transformer stability and efficiency. Insulation materials can effectively block this potential current path, preventing electromagnetic interference. Therefore, when splicing the annealed silicon steel and amorphous iron core frames, insulating material can be used to create a barrier between the two before assembly. Commonly used insulating materials include insulating paper and mica sheets. Insulating paper, for example, offers excellent insulation properties and a certain degree of flexibility, allowing it to be cut to fit the core frame shape. In practice, the cut insulating paper is evenly applied to the joint surface between the silicon steel and amorphous iron core frames, ensuring complete coverage of the contact area. The two are then spliced ​​together, sandwiching the insulating paper between them to form a reliable insulation barrier.

[0035] In one embodiment, assembly is the process of combining multiple core single frames in a certain arrangement to form a three-dimensional structure. During the assembly process, it is necessary to ensure that the positions of the various core single frames are accurate and the connections between each other are tight. The curing treatment is to fix the assembled core single frames into a whole by using adhesives or other curing methods, thereby improving the structural strength and stability of the three-dimensional wound core. For example, on a transformer core production line, multiple core single frames of the same specifications are assembled in a triangular arrangement, and then a high-strength epoxy resin adhesive is applied to the joints of the core single frames. After a certain period of curing reaction, the adhesive is hardened, and the three-dimensional wound core is firmly fixed into shape, thereby meeting the transformer's requirements for core structural strength and magnetic properties.

[0036] In one embodiment, assembly is the process of combining multiple prepared core frames in a specific arrangement to form a three-dimensional structure. These core frames are typically semi-finished products obtained through a series of previous processes (such as material preparation, cutting, winding, annealing, etc.). Assembly combines the individual frames in an orderly manner, enabling them to work together. The purpose of the curing process is to securely fasten the assembled core frames into a single unit using adhesives or other curing methods. Because the assembled core frames rely solely on mechanical contact, their integrity and stability are relatively weak. The curing process can improve the structural strength and stability of the three-dimensional wound core, enabling it to withstand various external forces such as electromagnetic force, vibration, and mechanical stress generated during transformer operation, ensuring long-term reliable operation of the transformer. For example, in actual production, a high-strength epoxy resin adhesive can be used. This adhesive is evenly applied to the joints of the core frames. After a certain period of curing reaction, the adhesive gradually hardens, firmly bonding the individual core frames together to form a solid whole.

[0037] In one embodiment, when the core frames are assembled, insulating materials can be used to block them. It is understandable that during the operation of the transformer, an alternating magnetic field exists inside the core, which generates an induced electromotive force and an induced current in the core. If there is no insulation barrier between the core frames, these induced currents may form a circulation between different frames, resulting in additional energy loss and reducing the efficiency of the transformer. It may also cause local overheating, affecting the normal operation and service life of the transformer. Using insulating materials to block can effectively cut off the circulation path that may be formed, reduce energy loss, and improve the electrical performance and operational stability of the transformer.

[0038] See also Figure 2 , Figure 2 This is an overall structural diagram of a three-dimensional wound core provided by an embodiment of the present application. The three-dimensional wound core 200 can be prepared by applying the three-dimensional wound core manufacturing method described above. Figure 3 As shown, it is primarily composed of multiple interconnected core frames 310. Each core frame 310 further includes a silicon steel core frame 320 and an amorphous core frame 330. The silicon steel core frame 320 is provided with an embedded structure 321. The width of this embedded structure 321 precisely matches the frame width of the amorphous core frame 330. The amorphous core frame 330 can be tightly interlocked with the silicon steel core frame 320 through this embedded structure 321, thus forming a complete core frame 310. This interlocking method ensures a stable connection between the silicon steel core frame 320 and the amorphous core frame 330.

[0039] In one embodiment, multiple core single frames 310 composed of the above structure are assembled to finally obtain Figure 2 During the assembly process, the splicing positions and angles of the core single frames 310 must be strictly in accordance with the design requirements to ensure the structural integrity and consistency of the magnetic properties of the entire three-dimensional wound core.

[0040] It should be noted that since the three-dimensional wound core of this embodiment can be prepared using the three-dimensional wound core manufacturing method described above, the three-dimensional wound core of this embodiment and the three-dimensional wound core manufacturing method of the previous embodiment have the same technical principles and the same beneficial effects. In order to avoid repetition, they will not be repeated here.

[0041] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present application. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application is not limited to the embodiments shown herein, but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for manufacturing a three-dimensional wound core, characterized in that: include: Obtain silicon steel material and amorphous material for preparing the iron core; Cutting the silicon steel material and the amorphous material respectively to obtain silicon steel strip material and amorphous strip material; Using the silicon steel strip material to wind a silicon steel core frame with an embedded structure, and using the amorphous strip material to wind an amorphous core frame, wherein the frame side width of the amorphous core frame matches the width of the embedded structure; Annealing the silicon steel core frame and the amorphous iron core frame respectively, and splicing the annealed silicon steel core frame and the amorphous iron core frame to obtain a single core frame; The core single frames are assembled and cured to obtain a three-dimensional wound core.

2. The method for manufacturing a three-dimensional wound core according to claim 1, wherein: The annealing treatment is performed on the silicon steel core frame and the amorphous iron core frame respectively, comprising: The amorphous core frame is sent to a first annealing furnace for annealing, and magnetization is performed during the annealing process. The annealing temperature range of the first annealing furnace is 300° C. to 500° C.; The silicon steel core frame is sent to a second annealing furnace for annealing. The annealing temperature of the second annealing furnace is in the range of 700°C to 900°C.

3. The method for manufacturing a three-dimensional wound core according to claim 1, wherein: After annealing the silicon steel core frame and the amorphous iron core frame, the method further includes: The amorphous core frame is subjected to wrapping or curing treatment.

4. The method for manufacturing a three-dimensional wound core according to claim 3, wherein: The step of curing the amorphous core frame includes: applying core paint or core glue on the surface of the amorphous core frame.

5. The method for manufacturing a three-dimensional wound core according to claim 1, wherein: The step of splicing the annealed silicon steel core frame and the amorphous iron core frame comprises: performing insulation treatment between the silicon steel core frame and the amorphous iron core frame and then assembling them.

6. The method for manufacturing a three-dimensional wound core according to claim 1, wherein: The step of assembling the core single frames includes: performing insulation treatment on the core single frames and then assembling them.

7. A three-dimensional wound core, characterized in that: A method for manufacturing a three-dimensional wound core according to any one of claims 1 to 6 is applied, wherein the three-dimensional wound core includes a plurality of mutually spliced ​​core single frames, the core single frames including a silicon steel core frame and an amorphous core frame, the silicon steel core frame is provided with an embedded structure, the frame edge width of the amorphous core frame matches the width of the embedded structure, and the amorphous core frame is embedded with the silicon steel core frame through the embedded structure.

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