Amorphous transformer

Abstract

To improve an insulation material interposed between wound cores to be made to self-stand in an amorphous transformer for making the wound cores self-stand and fixing the wound cores.SOLUTION: Non-magnetic insulation materials are interposed between facing surfaces of wound cores 21 to 24 arranged in parallel in a lamination direction and a parallel direction. The insulation materials are formed respectively so as to be separated into an upper side insulation material 30 and a lower side insulation material 40 and an upper side insulation material 60 and a lower side insulation material 70 that have different heatproof temperatures, and the insulation materials are formed in a T shape or a cross shape using an FRP flat plate. The upper side insulation materials 30, 60 which are easily to be at high temperatures are manufactured using materials having heat resistance higher than that of the lower side insulation materials 40, 60. The lower side insulation materials 40, 70 are fixed to steel material bases 50, 80 on which the wound cores 21 to 24 are mounted, so that the wound cores 21 to 24 are preferably supported.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a technology for providing an amorphous transformer, and particularly to an improvement of a support member when assembling an amorphous core independently.

Background Art

[0002] In recent years, transformers using non-crystalline magnetic alloys and amorphous materials have been developed. When an amorphous material is adopted for a transformer core, a support member is required for each core in order to assemble the core independently. As such a support member, Patent Document 1 discloses using a corner support member for improving the sagging of each corner portion of the core when standing independently and for smoothly assembling the core and the coil, and a plate-shaped core support member fixed to the corner support member.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Patent Document 1 does not disclose the material of the core support member. According to the study by the inventors, it has been found that the following problems exist in the selection of the material of the support member for making the amorphous core stand independently. The core support member requires strength to make the core stand independently, and the adoption of steel material is considered. However, if a steel material (magnetic material) is adopted for the core support member, eddy currents will be generated due to the magnetic flux generated in the coil, causing local heating, generating combustible gas, and possibly causing abnormalities in the transformer. Also, as a material to be adopted for the core support member, a resin material is considered, but a resin material with high heat resistance has lower strength than steel material, and there is a possibility that the transformer will be enlarged as a whole and the cost will increase.

[0005] While recent transformers aim for increased capacity, space constraints make it crucial to avoid large transformers and instead maintain a compact design. As the core volume increases, the core's weight, as well as the coil dimensions and weight, are increased, making the assembly process of inserting the coils into the core more difficult. Furthermore, measures will be needed to ensure the core remains stable and self-supporting during and after assembly.

[0006] This invention was made in view of the above background, and the object of this invention is to realize an amorphous transformer that can hold multiple iron cores in a self-supporting state at appropriate intervals. Another object of the present invention is to realize an amorphous transformer that allows for smooth assembly of iron cores and coils by forming an insulating plate interposed between multiple iron cores in an upper and lower division. Another object of the present invention is to realize an amorphous transformer in which the insulating plate on the side of the upper and lower divided insulating plates that is more prone to temperature rise is made of a material with a higher heat resistance temperature. [Means for solving the problem]

[0007] This invention was made to achieve the above objective, and its representative features are as follows. According to one feature of the present invention, an amorphous transformer is provided comprising a plurality of amorphous winding cores arranged in a stacking direction and a parallel direction, a support member that makes the winding cores self-supporting, a coil formed by winding over one of the legs of the plurality of winding cores, and an upper and lower clamping fitting for fixing the winding cores, wherein an insulating material is provided to maintain a constant interval between the end faces of the legs of adjacent winding cores in the stacking direction and a constant interval between the side surfaces of the legs of adjacent winding cores in the parallel direction. This insulating material is formed by dividing it into a lower insulating material fixed to the support member and an upper insulating material with a different heat resistance temperature from the lower insulating material. The insulating material is made of resin or resin containing reinforcing fibers, and the upper insulating material is formed to have a higher heat resistance temperature than the lower insulating material. The upper insulating material is fixed by an upper clamping fitting so as to be sandwiched between two winding cores at a position with a gap between it and the lower insulating material.

[0008] According to another feature of the present invention, the upper and lower insulating materials are flat plates made of FRP (Fiber Reinforced Plastics), the upper and lower insulating materials in contact with the magnetic legs that penetrate the coil are cross-shaped, and the upper and lower insulating materials in contact with the magnetic legs that do not penetrate the coil are T-shaped. The upper ends of the cross-shaped lower insulating material and the T-shaped lower insulating material should be positioned above the center of gravity of the wound core when viewed in the vertical direction. The cross-shaped upper insulating material and the cross-shaped lower insulating material are assembled by preparing two rectangular plates with slits extending vertically from the center of one of the short sides of each rectangular plate, and then fitting the slits of the two rectangular plates together to form a cross shape when they intersect. On the other hand, the T-shaped upper insulating material and the cross-shaped lower insulating material are assembled by joining two plates together with adhesive or by fitting them together with slits. [Effects of the Invention]

[0009] According to the present invention, it is possible to make amorphous wound cores self-supporting, and by using upper and lower insulating materials in combination, multiple wound cores can be held at predetermined intervals in a self-supporting state. Furthermore, since the lower portion of the wound core and the lower insulating material can be fixed to the support member, the insertion of the coil and the joining of the overlapping portion of the wound core can be performed, making the assembly work of inserting the coil into the core easier. In addition, by using a heat-resistant material for the insulating plate, the constraints on the temperature rise of the transformer cooling medium (oil) are reduced, making it possible to make even large-capacity transformers more compact by reducing the number of coolers. In particular, by forming the insulating plate in upper and lower sections, it is possible to use a material with properties suitable for the temperature distribution during transformer operation, and manufacturing costs can be reduced. As a result, it is possible to maintain good transformer characteristics even when the transformer capacity is increased. [Brief explanation of the drawing]

[0010] [Figure 1] This is a perspective view of an amorphous transformer 1 according to an embodiment of the present invention. [Figure 2] Figure 1 is a cross-sectional perspective view of amorphous transformer 1. [Figure 3] Figure 3A is a perspective view of the insulating materials 30 and 40 and the steel base 50 shown in Figure 2, and Figure 3B is a perspective view of the insulating materials 60 and 70 and the steel base 80. [Figure 4] Figure 4 is an unfolded view of the lower insulating material 40 shown in Figure 3A. [Figure 5] Figure 5A is an exploded view showing the mounting structure of the lower insulating material 40 and the steel base 50, and Figure 5B is an exploded view showing the mounting structure of the lower insulating material 70 and the steel base 80. [Figure 6] This table shows examples of material combinations for the upper insulating materials 30 and 60 and the lower insulating materials 40 and 70. [Figure 7] This is a perspective view of an amorphous transformer 101 according to a second embodiment of the present invention. [Figure 8] This is a perspective view of an amorphous transformer 201 according to a third embodiment of the present invention. [Modes for carrying out the invention]

[0011] Embodiments of the present invention will be described below with reference to the drawings. In the following figures, the same parts are denoted by the same reference numerals, and repeated descriptions will be omitted. In this specification, the front / back, left / right, and up / down directions are described as the directions shown in the figures. In addition, in the alignment of the wound cores 21-24, the stacking direction and the parallel direction are described as the directions shown in the figures. [Examples]

[0012] Figure 1 is a perspective view showing the entire amorphous transformer 1 according to an embodiment of the present invention. The amorphous transformer 1 shown in Figure 1 is a single-phase external iron type and is mainly composed of a coil 10 and amorphous iron cores 2 (winding cores 21, 23, etc.). Hereafter, in this specification, when referring to the entire set of winding cores 21 to 24, it will simply be referred to as "iron core 2," and when referring to individual parts of the iron core 2, they will be divided into reference numerals such as 21 to 24 and referred to as "winding cores 21 to 24." The winding cores 21 to 24 (reference numerals 22 and 23 are shown in Figure 2 below) are formed in an annular shape and are made of an amorphous magnetic alloy, for example, an amorphous metal mainly composed of iron. Amorphous metals have a different arrangement of atoms inside the material compared to ordinary metals. When heated, metals form crystals as they cool. However, if they are cooled so rapidly that there is no time for crystals to form, they become amorphous metals that do not have a crystalline structure. The wound cores 21-24 (see Figure 2 below for 22 and 24) form a closed magnetic circuit and are manufactured using a known amorphous core manufacturing process. Insulating materials 30, 40 (see Figure 2), 60, and 70 are interposed between adjacent cores 2 in the stacking direction, maintaining a small gap between the wound cores 22-24 that make up the core 2.

[0013] The coil 10 is arranged to surround the adjacent magnetic legs of the iron core 2 as shown in Figure 1. The iron core 2 is positioned on a steel support member (steel base 80, etc.) with two wound iron cores arranged in the stacking direction and two in the parallel direction, and the upper and lower parts of the iron core 2 are fixed by an upper fastening fitting 15 and a lower fastening fitting 16.

[0014] FIG. 2 is a cross-sectional perspective view of the vicinity of the core 2 and the coil 11 of the amorphous transformer 1. FIG. 2 is a view in which the upper fastening metal fitting 15, the lower fastening metal fitting 16, and the wound core 23 are removed from the state of FIG. 1, and further, a part is shown in cross section. The shape of the wound core 23 (see FIG. 1) not shown is the same as those of the other wound cores 21, 22, 24, and these can be formed as common parts. Incidentally, the wound cores 21 to 24 are formed in a split form for the insertion of the coil, and after the coil 10 is inserted into the magnetic leg portions of the wound cores 21 to 24, the removed portions (lap portions) of the split wound cores 21 to 24 are joined to each other, but the joining locations and the joining structure are not shown in FIG. 2.

[0015] The core 2 arranges two wound cores 21 and 22 in the stacking direction (the front-rear direction in FIG. 1), and arranges the wound cores 23 and 24 so as to be adjacent to them in the parallel direction (the left-right direction in FIG. 2). The coil 10 is arranged so as to wind around one magnetic leg portion of the four wound cores 21 to 24. The rear end face of the wound core 21 and the front end face of the wound core 22 are arranged to face each other with a slight distance therebetween, and the rear end face of the wound core 23 (not shown) and the front end face of the wound core 24 are arranged to face each other with a slight distance therebetween. Between the wound cores 21 to 24 arranged with these distances therebetween, insulating members (upper insulating material 30 and lower insulating material 40) made of a non-magnetic material are interposed. Also, insulating members (upper insulating material 60 and lower insulating material 70) are provided in the gap portions of the magnetic leg portions (the portions extending in the vertical direction of the wound core) in the vertical direction on the side where the coil 10 is not wound between the wound core 21 and the wound core 22. Similarly, insulating members (upper insulating material 60 and lower insulating material 70) are provided in the gap portions of the magnetic leg portions extending in the vertical direction on the side where the coil 10 is not wound between the wound core 23 and the wound core 24 whose illustration is omitted. The upper insulating material 30 and the lower insulating material 40 are in a non-contact state and are arranged with a distance S therebetween in the vertical direction. Similarly, the upper insulating material 60 and the lower insulating material 70 are in a non-contact state and are arranged with a distance S therebetween in the vertical direction.

[0016] At the lower corner portions of the wound cores 21 to 24, one steel base 50 and two steel bases 80 are provided to make the wound cores 21 to 24 stand independently in the vertical direction. In this specification, when the steel bases 50 and 80 of the amorphous transformer 1 are placed on the floor surface or the like, the side where the steel bases 50 and 80 are located is called the lower side, and the side far from the steel bases 50 and 80 is called the upper side. The steel bases 50 and 80 are formed by a plurality of plates (described later in FIGS. 3A and 3B) having a contour along the shape of the lower arc-shaped corner portions of the wound cores 21 to 24.

[0017] The coil 10 is formed so as to surround the right magnetic leg portions extending in the vertical direction of the wound cores 21 and 22 and the left magnetic leg portions extending in the vertical direction of the wound cores 23 and 24. The coil 10 in FIG. 2 is formed by winding an enameled wire and is only schematically shown in terms of its outer contour. The coil 10 includes a primary coil and a secondary coil, and the specific winding method and arrangement are not shown. The winding method of the coil 10 may adopt a known method, and any of overlapping winding, divided winding, bifilar winding, sandwich winding, etc. can be adopted.

[0018] The side surfaces of the magnetic leg portions of the wound cores 21 and 22 where the coil 10 is not wound and the side surfaces of the magnetic leg portions of the wound cores 23 and 24 where the coil 10 is not wound are covered with side plates (insulating plates 66 and 76). Here, the insulating plates 66 and 76 are made of the same insulating material (insulating plates 61 and 71 described later in FIG. 3B) as the other parts of the upper insulating material 60 and the lower insulating material 70 for ease of manufacture and are formed in a T shape when viewed from above. The lower insulating material 70 is fitted into the slit portion of the steel base 80 and fixed using fixing means (for example, bolts and nuts). The upper insulating material 60 and the lower insulating material 70 are located above the lower insulating material 70 in a non-contact state with a predetermined gap 69 therebetween as indicated by the arrow. The insulating materials 30 and 40 are cross-shaped when viewed from above, and each is arranged in a range that partially overlaps in the vertical direction within the internal space of the coil 10. On the other hand, the insulating materials 60 and 70 are arranged outside the coil 10.

[0019] The lower insulating material 40 is located in the center of the four wound cores 21-24 and is in contact with each of them. The lower insulating material 40 serves to support the wound cores 21-24 independently, and is formed to such a size that its upper end is positioned higher than the individual center of gravity of the wound cores 21-24 and the center of gravity of the entire core. In the example in Figure 1, if the height of the upper ends of the wound cores 21-24 is H, the height H1 of the upper end of the lower insulating material 40 (see Figure 3A for the symbol) is configured to satisfy the relationship H>H1>H / 2. Furthermore, if this height H1 is lower than the height H2 of the upper end of the coil 10, sufficient height can be secured for the upper insulating material 30.

[0020] The upper insulating material 30 is positioned above the lower insulating material 40. A predetermined gap S is formed between the upper insulating material 30 and the lower insulating material 40. The shapes of the upper insulating material 30 and the lower insulating material 40 are identical in a top view, and they are fixed so as to be sandwiched between the gaps of four adjacent wound cores 21 to 24. The upper insulating material 30 ensures that the wound cores 21 and 22 are stably held while maintaining a predetermined gap, that the wound cores 23 (see Figure 1) and 24 are stably held while maintaining a predetermined gap, and furthermore, that the wound cores 21 and 23, and the wound cores 22 and 24 are stably held while maintaining a predetermined gap, thus also functioning as a spacer.

[0021] Upper insulating material 60 and lower insulating material 70 are placed on the side surfaces (vertical portions of the outer circumferential surface) of the magnetic legs of the wound cores 21-24 that do not have coils wound on them. The upper insulating material 60 and lower insulating material 70, which are provided so as to be in contact with the end faces in the stacking direction and the side surfaces in the parallel direction of the wound cores 21 and 22, have the same shape as the upper insulating material 60 and lower insulating material 70, which are provided so as to be in contact with the end faces in the stacking direction and the side surfaces in the parallel direction of the wound cores 23 and 24, and common parts are used. Note that a portion of the upper insulating material 60 in contact with the wound cores 23 and 24, indicated by a dotted line, is omitted from the illustration, so please refer to Figure 3 described later for its shape. The steel bases 50 and 80 hold the wound cores 21-24 in a self-supporting state, and the outer circumferential surfaces of the wound cores 21-24 follow the curved surfaces of multiple plates, preventing them from sagging due to the weight of the corner portions of the outer circumferential surfaces. Furthermore, by manufacturing the steel bases 50 and 80 using multiple plates instead of a solid structure, the manufacturing cost of the steel bases 50 and 80 can be reduced compared to conventional designs. In addition, the steel bases 50 and 80 also function as a base to support the self-supporting lower insulating materials 40 and 70.

[0022] Figure 3A is a perspective view of insulating materials 30 and 40 arranged to penetrate the coil 10, and a steel base 50 that supports the wound cores 21-24 and the insulating material 40. The insulating members arranged to penetrate the coil 10 are formed in two parts: an upper insulating material 30 and a lower insulating material 40. The upper insulating material 30 is formed by combining two flat insulating plates 31 and 36, which are arranged to intersect in a cross shape. Similarly, the lower insulating material 40 is manufactured by combining two insulating plates 41 and 46, which are arranged to intersect in a cross shape. The insulating plates 31 (31a, 31b) and insulating plate 41 are placed between the end faces of adjacent cores, i.e., between wound cores 21 and 22, and between wound cores 23 and 24.

[0023] Here, the manufacturing method of the lower insulating material 40 will be explained using Figure 4. In Figure 4, the lower insulating material 40 is prepared as two thin rectangular insulating plates 41 and 46 made of glass epoxy FRP. A slit 43 is formed in the insulating plate 41, extending downward from the center of the upper short side 42a. Similarly, a slit 48 is formed in the insulating plate 46, extending upward from the center of the lower short side 47b. The vertical length of the slits 43 and 48 is half the height H1 of the insulating plates 41 and 46. Then, the insulating plates 41 and 46 are positioned perpendicular to each other as shown in Figure 3, and the insulating plates 41 and 46 are moved relative to each other in the direction indicated by arrows 49a and 49b so that the slits 43 and 48 engage. The shape after joining will be a cross shape when viewed from above, as shown in Figure 3A. The insulating plates 41 and 46 may be fixed to each other by some fixing means such as adhesive, or they may be left unfixed. Furthermore, the insulating plate 41 may be fixed to the steel base 50 so that the insulating plate 41 does not come off the insulating plate 46.

[0024] Returning to Figure 3A, the upper insulating material 30, like the lower insulating material 40, is made of FRP and can be assembled by providing slits in the plates. However, how the plates are combined to form the cross is arbitrary. Figure 3A shows an example where the upper insulating material 30 is manufactured using a different method than the lower insulating material 40. Specifically, insulating plates 31a and 31b, each half the size of insulating plate 36, are bonded to both sides of the central portion of a rectangular insulating plate 36 made of FRP from the left and right directions using adhesive. In this way, the upper insulating material 30, which is cross-shaped when viewed from above, is formed using any of these fixing methods.

[0025] Of the insulating plate 31 of the upper insulating material 30, the left half 31a is held by being sandwiched between the end faces of the wound cores 21 and 22, and the right half 31b is held by being sandwiched between the end faces of the wound cores 23 and 24. On the other hand, of the insulating plate 36, the front half 36a is held by being sandwiched between the sides of the wound cores 21 and 23, and the rear half 36b is held by being sandwiched between the sides of the wound cores 22 and 24. The upper insulating material 30 does not need to be fixed to the upper fastening fitting 15 (see Figure 1), and is indirectly fixed by the upper fastening fitting 15 (see Figure 1) by being sandwiched between the adjacent wound cores 21 and 22, and 23 and 24. Alternatively, the upper insulating material 30 may be fixed to the upper fastening fitting 15 (see Figure 1) using screws, bolts, or other fastening means.

[0026] The steel base 50 is not formed from a solid member, but is constructed by combining a total of 12 small steel plates 51a to 56a, 51b to 56b (see Figure 5A below for symbols not shown). By using the steel base 50, the corners of the wound cores 21 and 22 can be prevented from sagging due to their own weight, and it can also be used as a holding member for the core 2 when the coil 10 is mounted during the assembly process.

[0027] Figure 3B is a perspective view of the insulating materials 60 and 70, which are placed on the magnetic legs that are not penetrated by the coil 10, and the steel base 80 that supports the wound cores 21-24 and the insulating material 70. The insulating materials 60 and 70 are placed on the sides of the magnetic legs of the wound cores 21-24 that are not wound with the coil 10 (open sides where the wound cores are not adjacent), and are formed in a T-shape rather than a cross shape when viewed from above. When the upper insulating material 60 is placed to the right of the wound cores 23 and 24 (see Figures 1 and 2), the insulating plate 61 is placed between the adjacent end faces of the wound cores 23 and 24. The insulating plate 66 functions as a side plate or cover material that covers the exposed sides of the wound cores 23 and 24. The lower insulating material 70 is similar, and is formed by an insulating plate 71 positioned between adjacent end faces in the stacking direction of the wound cores 23 and 24 (see Figures 1 and 2), and a side plate (insulating plate 76) provided to cover the sides of the wound cores 23 and 24. Here, since the insulating plates 66 and 76 are not provided in the gaps between adjacent cores, their installation can be omitted. Also, since they are located on the outside, they may be manufactured from a different material than the insulating plates 66 and 76. However, in this embodiment, insulating plates 66 and 76 were manufactured from the same material as insulating plates 61 and 71 for the reason of fixing insulating plates 61 and 66, and 71 and 76, for ease of manufacture, and due to the requirement of heat resistance.

[0028] The lower insulating material 70 is fixed to stand on its own by a steel base 80. The steel base 80 is constructed by connecting six plates 81 to 86 perpendicularly to an L-shaped base 87. By using the steel base 80, the corners of the wound cores 23 and 24 (see Figures 1 and 2) can be securely fixed.

[0029] Figure 5A is an unfolded view of the lower insulating material 40 and steel base 50 shown in Figure 3A. The lower insulating material 40 is inserted into the steel base 50 in the direction of arrow 59 after insulating plates 41 and 46 are assembled in a cross shape, and is fixed with bolts (not shown). The steel base 50 is made by fixing plates 51a to 56a and 51b to 56b so as to extend perpendicularly to a thick, rectangular flat plate base plate 57. Steel is used for the base plate 57, plates 51a to 56a and 51b to 56b, and they are connected by welding.

[0030] The plates 51a-56a and 51b-56b are roughly right-angled triangles, with the hypotenuse not being straight but forming a gentle curve along the contour of the lower corners of the wound cores 21-24. Since plates 51a-56a and 51b-56b are identical in shape, it is sufficient to prepare many single parts. Plates 51a and 51b are welded together such that a gap 51c corresponding to the thickness of the insulating plate 46 is formed in the stacking direction. Similarly, after the placement of the remaining plates 52a-56a and 52b-56b, gaps 52c-56c corresponding to the thickness of the insulating plate 46 are formed. The size of the gaps 52c-56c is set so that the insulating plate 46 can be inserted in the direction of arrow 59 without any rattling after insertion.

[0031] Plates 53a and 54a are formed to have a gap 58a equal to the thickness of the insulating plate 41 in the stacking direction, and plates 53b and 54b are formed to have a gap 58b equal to the thickness of the insulating plate 41 in the stacking direction. These gaps 58a and 58b are set to allow the insulating plate 41 to be inserted in the direction of arrow 59, and to the extent that there is no rattling after insertion. Bolt holes 53d and 54d (54d is not visible in Figure 5A) are formed in plates 53b and 54b, and bolts (not shown) are passed through bolt holes 53d and 54d and bolt hole 44, and fixed with nuts (not shown).

[0032] Plates 51a to 53a are arranged parallel to each other at equal intervals in the stacking direction, and plates 51b to 53b are arranged parallel to each other at equal intervals in the stacking direction. Similarly, plates 54a to 56a are arranged parallel to each other at equal intervals in the stacking direction, and plates 54b to 56b are arranged parallel to each other at equal intervals in the stacking direction. As described above, the steel base 50 only needs to use three plates (plates 51a to 53a for the winding core 21) to hold one corner of one winding core (for example, winding core 21), so the steel base 50 can be made lighter compared to a method of manufacturing the steel base 50 from solid steel. In addition, since 12 plates 51a to 56a and 51b to 26b are welded to the base 57, a strong self-supporting fixing member for the core 2 can be easily realized.

[0033] Figure 5B is an unfolded view of the lower insulating material 70 and steel base 80 shown in Figure 3. Near the top of the insulating plate 71 of the lower insulating material 70, a projection 73 corresponding to the thickness of the insulating plate 76 is formed, as shown by the dotted line, and partially engages with a slit 78 formed downward from the center of the upper edge of the insulating plate 76. By fitting a part of the insulating plate 71 (projection 73) and a part of the insulating plate (slit 78) in this way, the vertical movement of the insulating plate 76 can be more reliably restricted when the insulating plate 71 is bolted to the steel base 80.

[0034] The steel base 80 has almost the same shape as the steel base 50 cut in half in a parallel direction. The only difference from the shape of the steel base 50 cut in half is that the base 87 is not a flat plate like half of the substrate 57, but is formed in an L-shape when viewed from the front or rear by a horizontal plate 87a and a vertical plate 87b extending in the vertical direction. A gap 81a to 86a equal to the thickness of the insulating plate 76 is secured between the vertically extending sides (elongated surfaces) of plates 81 to 86 and the vertical plate 87b. Plates 81 to 83 are arranged parallel to each other at equal intervals in the stacking direction, and plates 84 to 86 are arranged parallel to each other at equal intervals in the stacking direction. Also, plates 83 and 84 are arranged parallel to each other in the stacking direction separated by the thickness of the insulating plate 71. An insulating plate 71 can be inserted in the direction of arrow 89 into the gap 88 between plates 83 and 84, and an insulating plate 76 can be inserted in the direction of arrow 89 into the gaps 81a to 86a between plates 81 to 86 and the vertical plate 87b. Bolt holes 83c and 84c (84c is not visible in Figure 5B) are formed in plates 83 and 84, and the lower insulating material 70 and the steel base 80 are fixed by passing bolts (not shown) through bolt holes 83c, 84c and bolt hole 74 and securing them with nuts (not shown).

[0035] A gap 81a to 86a equal to the thickness of the insulating plate 76 is formed between the vertical sides of plates 81 to 86 and the vertical plate 87b. By inserting the insulating plate 76 in the direction of arrow 89 into these gaps, the insulating plate 76 is held in place by the steel base 80. In this way, the steel base 80 is used to fix the wound cores 23, 24 (or 21, 22), but it can also be used as a fixing member for the lower insulating material 70.

[0036] Figure 6 is a table showing examples of material combinations for the upper insulating materials 30, 60 and the lower insulating materials 40, 70. In Figure 6, Example 1 uses different materials from Example 1 shown in Figures 2 to 5. For the upper insulating materials 30, 60, heat-resistant press board with a heat resistance of 220°C is used, and for the lower insulating materials 40, 70, glass epoxy-based FRP insulating material with a heat resistance of 180°C is used. The thickness of each plate is, for example, about 1 cm for amorphous transformer 1 with a height H of about 1 to 2 m. The present invention is not limited to the materials of Example 1, and the insulating plates may be manufactured from other non-conductive materials. In Example 2, the upper insulating materials 30, 60 are made of ceramic with a very high heat resistance (for example, well over 200°C), and the lower insulating materials 40, 70 are made of glass-based epoxy-based FRP with a heat resistance of 180°C. Example 2 is effective when the temperature rise of the upper part of the wound cores 21 to 24 is particularly severe. Furthermore, even if it is made of ceramic, it is important that it has a strength above a certain level, and that sufficient consideration is given to preventing the insulating plate from cracking if the amorphous transformer 1 is subjected to a strong impact when switching the electrical circuit.

[0037] Example 3 uses synthetic resin with a heat resistance of Class B (130°C) for the upper insulating materials 30 and 60, and synthetic resin with a heat resistance of Class E (120°C) for the lower insulating materials 40 and 70. Amorphous transformers may exhibit a gentler temperature rise in the wound core depending on their shape and the amount of current flowing through them. In such cases, synthetic resin with an even lower heat resistance than that used in Example 3 (for example, Class A with a maximum allowable temperature of 105°C or higher) may be used.

[0038] Figure 6 shows three material examples, but it is also possible to use insulating materials with heat resistance temperatures other than those exemplified, and combinations of insulating materials other than those exemplified. For example, it is possible to form the insulating material using glass phenol-based FRP. Furthermore, since most of the upper insulating material 30 and the lower insulating material 40 will be placed inside the coil 10, it is even more preferable to manufacture them from materials that not only satisfy the required insulating properties and heat resistance temperature but also have a relative permittivity of about 2.5 to 8. [Examples]

[0039] Next, an amorphous transformer 101 according to a second embodiment of the present invention will be described using Figure 7. The amorphous transformer 101 shown in Figure 7 is a three-phase external iron type. Here, three coils 11 to 13 are used for the U phase, V phase, and W phase. A total of eight amorphous cores 21 to 28, as shown in Figure 7, are used to wind the coils 11 to 13. Cores 21 and 22, 23 and 24, 25 and 26, and 27 and 28 are arranged so that their end faces are adjacent in the stacking direction. Cores 21, 23, 25, and 27 are arranged so that their sides are adjacent at predetermined intervals in the parallel direction, and cores 22, 24, 26, and 28 are arranged so that their sides are adjacent at predetermined intervals in the parallel direction. Note that in Figure 7, the fastening fittings corresponding to the upper fastening fitting 15 and lower fastening fitting 16 in Figure 1 are omitted from the illustration.

[0040] Inside coil 11, one magnetic leg of each of the four wound cores 21-24 is positioned, with an upper insulating material 30 and a lower insulating material 40 positioned between them. The lower insulating material 40 is fixed to a steel base 50. Similarly, the other magnetic legs of two wound cores 23 and 24 and one magnetic leg of two wound cores 25 and 26 are positioned inside coil 12. An upper insulating material 30 and a lower insulating material 40 are positioned between them. This lower insulating material 40 is fixed to a steel base 50. Furthermore, similarly, the other magnetic legs of two wound cores 25 and 26 and one magnetic leg of two wound cores 27 and 28 are positioned inside coil 13. An upper insulating material 30 and a lower insulating material 40 are positioned between them. This lower insulating material 40 is fixed to a steel base 50. The upper insulating material 30 and the lower insulating material 40, which are placed inside coils 11, 12, and 13, are the same as those shown in Figures 2 to 5.

[0041] Between the two magnetic legs of the wound cores 21 and 22, which are located on the outside of the coil 11, are provided an insulating plate 61 of the upper insulating material 60 and an insulating plate 71 of the lower insulating material 71 (not visible in Figure 7). The lower insulating material 70 is fixed to the steel base 80. Similarly, between the magnetic legs of the wound cores 27 and 28, which are located on the outside of the coil 11, are provided an insulating plate 61 of the upper insulating material 60 and an insulating plate 71 of the lower insulating material 70. The lower insulating material 70 is fixed to the steel base 80.

[0042] By configuring the system as described above, it becomes possible to manufacture a three-phase amorphous transformer 101 using the common components used to manufacture a single-phase amorphous transformer 1, namely an amorphous core, insulating materials (30, 40, 60, 70), and steel bases (50, 80). Similarly, it is also possible to manufacture a two-phase amorphous transformer using the common components used to manufacture a single-phase amorphous transformer 1. [Examples]

[0043] Figure 8 is a perspective view of an amorphous transformer 201 according to a third embodiment of the present invention. Except for the upper insulating plates 260 and 261, the other parts have the same configuration as the amorphous transformer 1 shown in Figures 1 and 2, and are denoted by the same reference numerals. That is, upper insulating plates 260 and 261 are used instead of the upper insulating material 30 shown in Figure 2. The upper insulating plate 260 is held between the end faces of the wound cores 21 and 22, and the upper insulating plate 261 is held between the end faces of the wound cores 23 and 24. In the third embodiment, insulating plates are not provided between the side surfaces of the upper portions of adjacent wound cores 21 and 23, and between the side surfaces of the upper portions of wound cores 22 and 24. However, insulating plates corresponding to the insulating plate 36 in Figure 2 may be provided.

[0044] The upper insulating plates 260 and 261 are formed in a U-shape when viewed from the front or rear in a side view. When the upper insulating plates 260 and 261 are made from a single plate in this way, the effect of protecting the overlapping portion (not shown) of the wound cores 21 to 24 can be obtained. A gap of distance S is formed between the upper insulating plates 260 and 261 and the lower insulating materials 40 and 70, maintaining a non-contact state. The upper insulating plates 260 and 261 are also kept non-contact, and a gap of distance S1 is formed between them. The upper insulating plates 260 and 261 may also be formed as a single continuous plate. By manufacturing the upper insulating plates 260 and 261 and the lower insulating materials 40 and 70 from different materials in this way, it becomes possible to easily meet the heat resistance temperature required for each insulating plate.

[0045] Although the present invention has been described above based on examples, the present invention is not limited to the above-described examples, and various modifications are possible without departing from the spirit of the invention. For example, the lower end of the upper insulating material (30, 60, 260, 261) and the upper end of the lower insulating material (40, 70) may be configured to be in contact with each other instead of being in a non-contact state. Also, the insulating members (30 and 40, 60 and 70) may be formed into three or more sections in the vertical direction instead of being divided into two sections, upper and lower, and insulating materials may be selected so that each section has a different heat resistance temperature. [Explanation of Symbols]

[0046] 1. Amorphous transformer 2 Iron core 10-13 coils 15. Upper fastening fitting 16. Lower fastening fitting 21-28 Turned Iron Core 30 Upper insulating material 31, 36 Insulating board 40 Lower insulating material 41, 46 Insulating board 43, 48 slits 44 bolt holes 50 Steel base 51a~56a Plate 51b~56b Plate 51cm~56cm gap 53d Bolt hole 57 circuit boards 58a, 58b gap 60 (2nd) Upper insulating material 61, 66 Insulating board 69 Gap 70 (2nd) Lower insulating material 71, 76 Insulating board 73 Protrusion 74 bolt holes 78 slits 80 Steel base Plates 81-86 81a~86a Gap 83c, 84c bolt holes 87 Base 87a horizontal board 87b Vertical plate 88 gaps 101, 201 Amorphous transformers 260, 261 Upper insulating plate

Claims

1. An amorphous transformer comprising: a plurality of amorphous winding cores arranged in a stacking direction and a parallel direction; support members that make the winding cores self-supporting; a coil formed by winding over any of the legs of the plurality of winding cores; and upper and lower clamping fittings for fixing the winding cores, An insulating material is provided to ensure that the end faces of the legs of adjacent wound cores in the stacking direction are maintained at a constant interval, and that the side surfaces of the legs of adjacent wound cores in the parallel direction are maintained at a constant interval. The insulating material is formed by dividing it into a lower insulating material fixed to the support member and an upper insulating material with a different heat resistance temperature from the lower insulating material. An amorphous transformer characterized in that the heat resistance temperature of the upper insulating material, which is the side that is more likely to experience a temperature rise during use, is higher than the heat resistance temperature of the lower insulating material.

2. The insulating material is made of resin or resin containing reinforcing fibers, The amorphous transformer according to claim 1, characterized in that the upper insulating material is fixed by the upper fastening fitting with a gap between it and the lower insulating material.

3. The upper and lower insulating materials are flat plates made of reinforced fiber plastic, formed in a T-shape or cross shape when viewed from above. The upper and lower insulating materials, which are in contact with the magnetic legs that penetrate the coil, are cross-shaped. The amorphous transformer according to claim 2, characterized in that the upper insulating material and the lower insulating material that are in contact with the magnetic legs that do not penetrate the coil are T-shaped.

4. The amorphous transformer according to claim 3, characterized in that the upper end position of the cross-shaped lower insulating material and the upper end position of the T-shaped lower insulating material are located above the center of gravity of the wound core when viewed in the vertical direction.

5. The amorphous transformer according to claim 4, characterized in that the cross-shaped upper insulating material and the cross-shaped lower insulating material are assembled by preparing two rectangular plates, each having a slit extending vertically from the center of one of the short sides, and then intersecting them so that the slits of the two rectangular plates fit together to form a cross shape.

6. The amorphous transformer according to claim 5, characterized in that the T-shaped upper insulating material and the cross-shaped lower insulating material are each made by joining two plate materials by adhesive.

7. The amorphous transformer according to claim 6, characterized in that the upper insulating material is a fiber-reinforced plastic with a heat resistance temperature of 105°C or higher.

8. An amorphous transformer comprising: a plurality of amorphous winding cores arranged in a stacking direction and / or parallel direction; support members that make the winding cores self-supporting; coils formed by winding so as to straddle the magnetic legs of adjacent winding cores; and upper and lower fastening fittings that fix the upper and lower sides of the winding cores, A plate-shaped first insulating member is interposed between opposing vertical surfaces so that the adjacent surfaces of the multiple winding cores wound around the coil are held at a constant interval. The first insulating member is made of reinforced fiber plastic and is formed by dividing it into a first upper insulating material that contacts the upper side of the wound core and a first lower insulating material that contacts the lower side of the wound core. An amorphous transformer characterized in that the position of division is set to be above the center of gravity of the wound core, and the heat resistance temperature of the first upper insulating material, which is the side that is more likely to heat up during use, is higher than the heat resistance temperature of the first lower insulating material.

9. The amorphous transformer according to claim 8, characterized in that the first upper insulating material is fixed by the upper fastening fitting and the first lower insulating material is fixed by the support member.

10. In the magnetic leg portion where the wound cores are arranged adjacent to each other in the stacking direction and in the parallel direction, The first upper insulating material, provided between the magnetic legs of the wound core wound in the coil, is arranged so as to intersect in a cross shape. The amorphous transformer according to claim 9, characterized in that the first lower insulating material, provided between the magnetic legs of the wound core wound in the coil, is arranged to intersect in a cross shape.

11. A plate-shaped second insulating member is provided on the vertical surface on the stacking direction side of the magnetic leg portion that is not wound in the coil and where the wound core is not adjacent in the parallel direction. The amorphous transformer according to claim 10, characterized in that the second insulating member is formed to the same thickness as the first insulating member and is fixed to the support member in a manner that it does not penetrate the coil.

12. The second insulating member is made of reinforced fiber plastic and is formed by dividing it into a second upper insulating material that contacts the upper side of the wound core and a second lower insulating material that contacts the lower side of the wound core. The amorphous transformer according to claim 11, characterized in that the position of division is set to be above the center of gravity of the wound core, and the heat resistance temperature of the second upper insulating material, which is the side that is more likely to heat up during use, is set to be higher than the heat resistance temperature of the second lower insulating material.

13. An insulating side plate is provided on the vertical side of the magnetic leg portion where the wound cores are not adjacent in the parallel direction. The amorphous transformer according to claim 12, characterized in that the side plate is fixed to the support member.

14. The amorphous transformer according to claim 13, characterized in that the side plate is formed by dividing it into an upper side plate that contacts the upper side of the wound core and a lower side plate that contacts the lower side of the wound core.

Images