Amorphous alloy three-dimensional wound core, manufacturing method thereof, and transformer

Abstract

The application discloses a manufacturing method of an amorphous alloy three-dimensional wound core, and relates to the technical field of transformers. The manufacturing method comprises the following steps: S1, winding an amorphous strip into a core cake with a circular ring-shaped cross section; S2, processing the core cake with the circular ring-shaped cross section into a frame-shaped core cake with a similar rectangular cross section; S3, stacking and solidifying a plurality of core cakes obtained in the step S2 to obtain a single-frame amorphous alloy core; and S4, splicing two of the three same single-frame amorphous alloy cores to obtain the amorphous alloy three-dimensional wound core. The application further discloses an amorphous alloy three-dimensional wound core and a transformer comprising the amorphous alloy three-dimensional wound core. The application can effectively improve the production efficiency of the amorphous alloy three-dimensional wound core and reduce the cost.

Description

Technical Field

[0001] This invention belongs to the field of transformer technology, specifically relating to an amorphous alloy three-dimensional wound core and its manufacturing method, as well as a transformer including the amorphous three-dimensional wound core. Background Technology

[0002] Unlike the planar wound core structure of traditional amorphous alloy transformers, the three-dimensional wound core transformer of amorphous alloy combines the low-cost advantage of three-dimensional wound core with the low-loss characteristics of amorphous alloy, which meets the development requirements of the national energy conservation and emission reduction policy and is currently receiving widespread attention in the transformer industry.

[0003] However, due to the immaturity of the domestic amorphous alloy three-dimensional wound iron core manufacturing level, the production efficiency is low and the manufacturing cost is high. Moreover, the amorphous alloy three-dimensional wound iron cores currently produced have at least the following shortcomings: high no-load loss, poor short-circuit resistance, and high noise. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to address the above-mentioned deficiencies in the prior art by providing a method for manufacturing an amorphous alloy three-dimensional wound iron core, an amorphous alloy three-dimensional wound iron core, and a transformer, which can effectively improve production efficiency and thereby reduce the production cost of the amorphous alloy three-dimensional wound iron core.

[0005] According to one aspect of the present invention, a method for manufacturing an amorphous alloy three-dimensional wound core is provided, the technical solution of which is as follows:

[0006] A method for manufacturing an amorphous alloy three-dimensional wound core includes:

[0007] S1, the amorphous ribbon is wound into a core disc with a circular cross-section;

[0008] S2, the iron core disc with a circular cross-section is processed into a frame-shaped iron core disc with a cross-sectional shape similar to a rectangle;

[0009] S3, after stacking and solidifying the multiple iron core cakes obtained in step S2, a single-frame amorphous alloy iron core is obtained;

[0010] S4. Three identical single-frame amorphous alloy cores are spliced ​​together in pairs to obtain amorphous alloy three-dimensional coiled cores.

[0011] Preferably, after step S2, the method further includes:

[0012] S201, the frame-shaped iron core cake is subjected to heat treatment annealing;

[0013] The heat treatment annealing temperature is 300-400℃, and the heat treatment annealing time is 50-150min.

[0014] Preferably, the heat treatment annealing process is carried out in a protective gas atmosphere, wherein the protective gas is nitrogen or an inert gas, and the heat treatment annealing process is carried out in a DC magnetic field environment.

[0015] Preferably, the curing temperature in step S3 is 60-150℃ and the curing time is 60-120min.

[0016] The method for manufacturing amorphous alloy three-dimensional coiled iron cores of the present invention is simple to operate, has high production efficiency, and is conducive to realizing automated production.

[0017] According to another aspect of the present invention, an amorphous alloy three-dimensional wound core is provided, the technical solution of which is as follows:

[0018] A three-dimensional coiled amorphous alloy core includes three identical single-frame amorphous alloy cores, which are spliced ​​together in pairs and arranged in a triangular pattern.

[0019] Each of the aforementioned single-frame amorphous alloy cores comprises multiple layers of core discs stacked together.

[0020] Each layer of the core disc has two first frame edges and two second frame edges. The first frame edges are used to form the core pillar of the single-frame amorphous alloy core, and the second frame edges are used to form the yoke of the single-frame amorphous alloy core.

[0021] The inner edge of the first frame is a straight edge, and the inner edge of the second frame is a rounded edge with a radius R of 500 ≤ R ≤ 3000 mm.

[0022] Preferably, the inner edges of the first frame and the second frame are connected by an arc, the radius r of which is 2≤r≤20mm.

[0023] Preferably, the cross-sectional shape of the core column is approximately semi-circular, and the semi-circular cross-section includes a splicing step edge, a first outer step edge, and a second outer step edge.

[0024] The splicing step edge includes multiple first steps, and the vertices of each first step are on the same straight line, which constitutes the diameter of the cross-section of the core column;

[0025] The first outer step edge includes multiple second steps, and the second outer step edge includes multiple third steps. The vertices of each second step and each third step are located on the same arc surface, which forms a semicircle of the cross-section of the core column.

[0026] Preferably, the three identical amorphous alloy cores are arranged in an equilateral triangle.

[0027] The angle between the splicing surface used for pairwise splicing in each single-frame amorphous alloy core and its yoke is 30°.

[0028] For two spliced ​​single-frame amorphous alloy iron cores, the vertex of the first step of one single-frame amorphous alloy iron core is connected to the vertex of the first step of the other single-frame amorphous alloy iron core.

[0029] Preferably, the amorphous alloy three-dimensional coiled core further includes an insulating component, which is disposed between the splicing surfaces of every two spliced ​​single-frame amorphous alloy cores.

[0030] The amorphous alloy three-dimensional wound core of the present invention has the advantages of low no-load loss, low noise, and strong short-circuit resistance, which can effectively improve operational safety.

[0031] According to another aspect of the present invention, a transformer is provided, the technical solution of which is as follows:

[0032] A transformer includes a core, wherein the core is an amorphous alloy three-dimensional wound core as described above.

[0033] The transformer of the present invention, due to the use of the above-mentioned amorphous alloy three-dimensional wound core, has the advantages of low no-load loss, low noise, and strong short-circuit resistance. Furthermore, since the core column is approximately cylindrical, the filling rate is high, which can reduce the amount of copper wire, transformer oil and other materials used, thereby reducing production costs. Attached Figure Description

[0034] Figure 1 This is a process flow diagram of the method for manufacturing amorphous alloy three-dimensional coiled iron core in an embodiment of the present invention;

[0035] Figure 2 This is a schematic diagram of the structure of the amorphous alloy three-dimensional wound iron core in an embodiment of the present invention;

[0036] Figure 3 This is a schematic diagram of the structure of the single-frame amorphous alloy coiled core in Embodiment 1 of the present invention;

[0037] Figure 4 for Figure 3 BB cross-sectional view;

[0038] Figure 5 This is a schematic cross-sectional view of the core column of a single-frame amorphous alloy coiled iron core in an embodiment of the present invention;

[0039] Figure 6 This is a schematic cross-sectional view of the yoke of the single-frame amorphous alloy coiled core in an embodiment of the present invention;

[0040] Figure 7 for Figure 3 AA section view;

[0041] Figure 8This is a schematic diagram of the iron core disc structure in an embodiment of the present invention;

[0042] Figure 9 for Figure 8 A schematic diagram of the structure of the iron core cake before it is processed and formed;

[0043] Figure 10 for Figure 2 A schematic diagram of the cross-section of the core column of a three-dimensional coiled amorphous alloy core;

[0044] Figure 11 for Figure 2 CC section view.

[0045] In the figure: 1-Support component; 2-Amorphous strip; 3-First frame edge; 4-Second frame edge; 5-Grounding component; 6-Splicing step edge; 71-First outer step edge; 72-Second outer step edge; 8-Insulating component; 9-Single frame amorphous alloy core; 10-Core disc; 30-Core column; 40-Yoke. Detailed Implementation

[0046] To enable those skilled in the art to better understand the technical solutions of the present invention, the present invention will be further described clearly and completely below in conjunction with the accompanying drawings and specific embodiments.

[0047] To address the problem of low production efficiency in existing methods for producing amorphous alloy three-dimensional wound cores, this invention provides a method for manufacturing amorphous alloy three-dimensional wound cores, comprising:

[0048] S1, the amorphous ribbon is wound into a core disc with a circular cross-section;

[0049] S2, the iron core disc with a circular cross-section is processed into a frame-shaped iron core disc with a cross-sectional shape similar to a rectangle;

[0050] S3, after stacking and solidifying the multiple iron core cakes obtained in step S2, a single-frame amorphous alloy iron core is obtained;

[0051] S4. Three identical single-frame amorphous alloy cores are spliced ​​together in pairs to obtain amorphous alloy three-dimensional coiled cores.

[0052] Accordingly, the present invention also provides an amorphous alloy three-dimensional coiled iron core, comprising three single-frame amorphous alloy iron cores, wherein the three single-frame amorphous alloy iron cores are spliced ​​together in pairs and arranged in a triangular pattern;

[0053] Each of the aforementioned single-frame amorphous alloy cores comprises multiple layers of core discs stacked together.

[0054] Each layer of the core disc has two first frame edges and two second frame edges. The first frame edges are used to form the core pillar of the single-frame amorphous alloy core, and the second frame edges are used to form the yoke of the single-frame amorphous alloy core.

[0055] The inner edge of the first frame is a straight edge, and the inner edge of the second frame is a rounded edge with a radius R of 500 ≤ R ≤ 3000 mm.

[0056] Accordingly, the present invention also provides a transformer comprising the above-mentioned amorphous alloy three-dimensional wound core.

[0057] Example 1

[0058] like Figure 1 As shown, this embodiment discloses a method for manufacturing an amorphous alloy three-dimensional wound core, including:

[0059] S1, the amorphous ribbon is wound into a core disc with a circular cross-section.

[0060] Specifically, first, silicon steel strip is wound into a ring with the required inner diameter to serve as a support. Then, a sufficient number of layers of amorphous ribbon are wound around the outer layer of this ring's silicon steel strip. The number of layers of amorphous ribbon (e.g., 1-20 layers) is determined based on the required outer diameter of the core disc. Next, several more layers (e.g., 1-3 layers) of silicon steel strip are wound around the outer layer of the wound amorphous ribbon to obtain a core disc with a circular cross-section and the required inner and outer diameters (e.g., ...). Figure 9 (As shown).

[0061] S2, then the iron core disc with a circular cross-section is processed into a frame-shaped iron core disc with a cross-sectional shape similar to a rectangle.

[0062] Specifically, the circular support square process is adopted, using forming equipment (such as forming machine) and mold to support the circular iron core disc from the inside out into a frame-shaped iron core disc similar to a rectangle.

[0063] It should be noted that in this embodiment, by changing the molds of different shapes and sizes, the circular iron core cake can be stretched from the inside out into a square or other shapes and sizes of frame-shaped iron core cakes.

[0064] Furthermore, after step S2, the process also includes: S201, heat treatment annealing of the frame-shaped iron core cake obtained above. The heat treatment annealing process can not only eliminate the internal stress generated during the winding and squaring of the iron core cake, which is beneficial to reduce the no-load loss of the iron core cake, but also shape the iron core cake, stabilize its size, prevent the iron core cake from rebounding and deforming, and improve the magnetic domain arrangement direction inside the amorphous ribbon in the iron core cake, thereby improving the magnetic permeability. The iron core cake formed after heat treatment annealing has strong stability and can be hoisted, moved and other operations.

[0065] In this embodiment, the heat treatment annealing temperature is preferably 300-400℃, and the heat treatment annealing time is preferably 50-150min.

[0066] In this embodiment, the heat treatment annealing process is carried out under a protective gas atmosphere, which is nitrogen or an inert gas, to prevent the core cake from rusting during the heat treatment annealing process.

[0067] In this embodiment, the heat treatment annealing process is carried out under DC magnetic field conditions, that is, a DC magnetic field is applied to the iron core cake to improve the working magnetic domain orientation of the amorphous ribbon in the iron core cake, thereby completely eliminating the forming stress of the iron core cake and improving the magnetic properties of the iron core cake.

[0068] S3. After stacking and solidifying the multiple iron core cakes obtained in step S2, a single-frame amorphous alloy iron core is obtained.

[0069] Specifically, determine the central symmetry point of each iron core disc, and determine the X-axis of symmetry passing through the central symmetry point (using...). Figure 8 Taking the core disc shown as an example, let the X-axis of symmetry be parallel to the first frame edge and the Y-axis of symmetry, which are perpendicular to the X-axis of symmetry. During stacking, first stack the outermost core disc located on any side of the single-frame amorphous alloy core, and coat the surface of the stacked core discs with resin glue or resin paint. Then, stack the remaining core discs sequentially, ensuring that the X and Y axes of symmetry of each layer of core discs coincide. This ensures that the dimensional deviation of the single-frame amorphous alloy core resulting from the stacking of each core disc is minimized, thereby achieving precise positioning and obtaining the stacked single-frame amorphous alloy core (e.g., ...). Figure 3 (As shown); then, the stacked single-frame amorphous alloy core is cured to solidify it into a stable whole and ensure that its electromagnetic properties remain unchanged. In actual operation, the stacking process of the core discs can be aided by automated positioning equipment to improve stacking efficiency and effectiveness.

[0070] In this embodiment, the curing temperature in step S3 is 60-150℃, and the curing time is 60-120 minutes. The curing process is preferably carried out in a tunnel-type oven.

[0071] S4. The three single-frame amorphous alloy cores are spliced ​​together in pairs to obtain a three-dimensional amorphous alloy coiled core.

[0072] Specifically, the process of splicing single-frame amorphous alloy cores in pairs can be achieved using specialized assembly equipment. Through a combination of operations such as flipping, translation, and positioning, an amorphous three-dimensional wound core (e.g., ...) can be obtained. Figure 2 (as shown); then, by any means such as dipping, brushing, or coating, a resin adhesive layer or resin paint layer is formed on the periphery of each single-frame amorphous alloy core in the amorphous alloy three-dimensional coiled core, so that the three single-frame amorphous alloy cores are cured into a whole, thereby improving the strength and short-circuit resistance of the amorphous alloy three-dimensional coiled core, as well as reducing the noise of the amorphous alloy three-dimensional coiled core.

[0073] The amorphous alloy three-dimensional wound core manufacturing method of this embodiment can effectively reduce the no-load loss and noise of the amorphous alloy three-dimensional wound core, improve the short-circuit resistance, and is simple to operate, has high production efficiency, and is also conducive to realizing automated production.

[0074] Example 2

[0075] like Figure 2 As shown, this embodiment discloses an amorphous alloy three-dimensional wound core, which can be manufactured using the amorphous alloy three-dimensional wound core manufacturing method described in Embodiment 1. It includes three identical single-frame amorphous alloy cores, which are spliced ​​together in pairs in a triangular arrangement. Every two single-frame amorphous alloy cores are spliced ​​together to form a core column of the amorphous alloy three-dimensional wound core. Each single-frame amorphous alloy core includes multiple layers of core discs 10 stacked together. Each core disc 10 has two first frame edges 3 and two second frame edges 4. The first frame edges 3 are used to form the core column 30 of the single-frame amorphous alloy core, which is used for winding coils. The second frame edges are used to form the yoke 40 of the single-frame amorphous alloy core, which mainly serves to close the magnetic circuit. The inner edge of the first frame edge 3 is a straight edge, and the inner edge of the second frame edge 4 is a rounded edge. That is, the yoke of the single-frame amorphous alloy iron core uses a rounded edge for transition to reduce the no-load loss of the single-frame amorphous alloy iron core. Furthermore, the radius R of the rounded edge is: 500≤R≤3000mm, so as to avoid R being too small, which would result in the distance between the two first frame edges 3 being too small and causing excessive internal stress in the iron core cake 10 during the winding process, and to avoid R being too large, which would result in the yoke of the single-frame amorphous alloy iron core being too long, so that the dimensions of the formed single-frame amorphous alloy iron core are more in line with the design requirements.

[0076] Furthermore, the inner edges of the first frame edge 3 and the second frame edge 4 are connected by an arc to reduce the generation of internal stress during the forming process of the single-frame amorphous alloy core, thereby further reducing the no-load loss. In addition, the radius r of the arc is 2≤r≤20mm, which can reduce the trimming process during the forming process of the single-frame amorphous alloy core and help improve production efficiency.

[0077] Specifically, the radius R of the arc edge (i.e. the inner edge of the second frame edge 4) can be 500mm, 1000mm, 1500mm, 1000mm, 2000mm, 2500mm, 3000mm, etc., or any other value within the range of 500mm to 3000mm. The specific value can be selected according to the capacity of the transformer to which it is applied.

[0078] Specifically, the radius r of the arc (i.e., the arc-shaped connection between the inner edge of the first frame edge 3 and the inner edge of the second frame edge 4) can be 2mm, 5mm, 10mm, 15mm, 20mm, etc., or any other value within the range of 2mm to 20mm. The specific value can be selected according to the capacity of the transformer to which it is applied.

[0079] Furthermore, the cross-section of the core column 30 is approximately semi-circular. This semi-circular cross-section includes a splicing step edge 6, a first outer step edge 71, and a second outer step edge 72. The splicing step edge 6 includes multiple first steps. The vertices of each first step lie on the same straight line, which forms the diameter of the cross-section of the core column 30. The first outer step edge 71 includes multiple second steps, and the second outer step edge 72 includes multiple third steps. The vertices of each second step and each third step lie on the same arc surface, which forms the semi-circle of the cross-section of the core column 30.

[0080] Specifically, such as Figure 4 , Figure 5 , Figure 6 , Figure 7 As shown, for each core disc 10 constituting a single-frame amorphous alloy core column, the distance from the inner edge to the outer edge of the first frame side 3 of each core disc 10 (i.e., the width of the first frame side 3) is different. In this embodiment, the number of winding layers for each core disc is 1-20. Figure 3 As shown, the width of the first frame edge 3 of each core disc 10 constituting the core column 30 increases sequentially from the outside to the middle, and the inner edges of the first frame edge 3 of each core disc constituting the core column 30 are on the same arc surface. The cross-section of the core column 30 of the single-frame amorphous alloy core is as follows: Figure 5 As shown, it is approximately semi-circular. The inner edges of the first frame edge 3 of each layer of core cake after stacking are distributed in a stepped manner, forming the second outer step edge 72. The inner edges of the first frame edge 3 of each layer of core cake that constitute the second outer step edge 72 are the third steps. The apex of the third step is on the same arc surface. The arc surface is the outer contour of the core column 30 of the single-frame amorphous alloy core, which is approximately semi-cylindrical. The outer edges of the first frame edge 3 of each layer of core cake are also distributed in a stepped manner, forming the splicing step edge 6 and the first outer step edge 71. Among them: the outer edges of the first frame edge 3 of each layer of core cake that constitute the splicing step edge 6 are the first steps, and the apex of the first step is on the same straight line; the outer edges of the first frame edge 3 of each layer of core cake that constitute the first outer step edge 71 are the second steps. The apex of the second step and the apex of the third step are on the same arc surface, that is, the apex of the second step is also on the outer contour of the core column 30 of the single-frame amorphous alloy core.

[0081] In this embodiment, the net height of the first frame edge 3 of each core disc 10 (i.e., the inner length of the first frame edge 3, also referring to the inner height of the core column of the single-frame amorphous alloy core) is the same, and the net height of the first frame edge 3 is preferably 50-2000mm. The inner radius of the second frame edge 4 of each core disc 10 is the same, so that the inner edge of the yoke 40 of the single-frame amorphous alloy core is on the same arc surface, and the cross-section of the yoke 40 is as follows. Figure 6As shown.

[0082] In this embodiment, the number of core cakes 10 in the single-frame amorphous alloy core can be selected according to the capacity of the transformer produced using it. For example, the number of core cakes 10 can be 3-100, and the net thickness of the single-frame amorphous alloy core (i.e., the height of the stack of multiple core cakes) is 50-1000mm.

[0083] In this embodiment, as Figure 8 As shown, each core cake 10 includes a wound amorphous ribbon and a support member wrapped around the surface of the amorphous ribbon. More precisely, the support member is located on the inner and outer sides of the wound amorphous ribbon. The support member 1 can provide support and protection, thereby improving the overall strength of the core cake. Each core cake 10 is annular, with two first frame edges 3 symmetrically arranged and two second frame edges 4 symmetrically arranged.

[0084] In this embodiment, the amorphous ribbon 2 is preferably made of iron-based amorphous alloy material, the thickness of the amorphous ribbon 2 is preferably 0.01-0.03 mm, and the width of the amorphous ribbon 2 is preferably 10-100 mm.

[0085] In this embodiment, the number of winding layers of each core disc 10 in the single-frame amorphous alloy core is preferably 1-20 layers. The number of winding layers of the amorphous strip affects the distance from the inner edge to the outer edge of the first frame edge 3 (i.e., the width of the first frame edge 3). In the same core column 30, the number of winding layers of each core disc increases from the outer layer (i.e.) towards the middle.

[0086] In this embodiment, the support member 1 is made of silicon steel strip or similar metal material, with a thickness of 0.1-1mm and a width that is adapted to the width of the amorphous strip 2 in the core cake 10.

[0087] In this embodiment, the single-frame amorphous alloy core further includes a curing layer (not shown in the figure). The curing layer is disposed between each core cake 10 and surrounds each core cake 10, so that each core cake is cured into a whole. In this embodiment, the curing layer can be cured using resin adhesive or resin paint.

[0088] In this embodiment, the single-frame amorphous alloy core also includes a grounding component 5, which is disposed on the iron yoke 40 and is used to ground the transformer during assembly to ensure the safety of the manufactured transformer.

[0089] Furthermore, in this embodiment, the three amorphous alloy cores in the amorphous alloy three-dimensional coiled core are arranged in an equilateral triangle. The angle between the splicing surface of each single-frame amorphous alloy core used for pairwise splicing and its yoke 40 is 30°. Each single-frame amorphous alloy core 9 has two splicing surfaces (i.e., splicing platform edges 6). The two splicing surfaces of the same single-frame amorphous alloy core are respectively spliced ​​with the splicing surfaces of two other single-frame amorphous alloy cores. The splicing surfaces of the two single-frame amorphous alloy cores used for splicing are symmetrical to each other. For any two spliced ​​single-frame amorphous alloy cores 9, the vertex of the first step of one single-frame amorphous alloy core connects with the vertex of the first step of the other single-frame amorphous alloy core. The resulting amorphous alloy three-dimensional coiled core is a three-phase, three-column three-dimensional structure. The cross-section of the amorphous alloy three-dimensional coiled core is an equilateral triangle (e.g., ...). Figure 11 As shown), the cross-section of the core column obtained after splicing is approximately circular (as shown). Figure 10 As shown in the figure, it can improve the filling rate of the core column, thereby reducing the required winding length and transformer oil volume, and thus reducing the production cost of amorphous alloy three-dimensional wound core and transformer.

[0090] Furthermore, the amorphous alloy three-dimensional wound core also includes an insulating component 8, which is located between the splicing surfaces of every two single-frame amorphous alloy cores to prevent the two adjacent single-frame amorphous alloy cores from directly contacting each other, thereby avoiding multi-point grounding caused by direct contact and preventing the transformer from burning out during operation.

[0091] In this embodiment, a curing layer (not shown in the figure) is also provided between and on the surface of each single-frame amorphous alloy core to fill the gaps, so that multiple single-frame amorphous alloy cores 9 are cured into a whole, thereby improving the strength and short-circuit resistance of the amorphous alloy three-dimensional wound core and reducing the noise of the amorphous alloy three-dimensional wound core. In this embodiment, the curing layer is preferably formed by curing resin paint or resin glue.

[0092] In this embodiment, the amorphous alloy three-dimensional coiled core may further include a fastener (not shown in the figure). The fastener may be a binding strap, which is made of insulating material and has a certain tensile strength. The binding strap is tied to the yoke 40 of the spliced ​​core column and each single-frame amorphous alloy core, which can further improve the overall strength of the combined splicing of multiple single-frame amorphous alloy cores.

[0093] The amorphous alloy three-dimensional wound core of this embodiment has advantages such as low no-load loss, low noise, and strong short-circuit resistance, which can effectively improve operational safety. Specifically, it is reflected in the following aspects:

[0094] (1) The iron yoke is a circular arc transition, which can reduce the internal stress of the amorphous strip and reduce the damage to the amorphous strip during the winding process, thereby reducing the no-load loss of the amorphous strip and reducing the trimming process during the winding process, which is conducive to improving production efficiency. In addition, the single-frame amorphous alloy iron core formed by circular arc transition is more in line with the design requirements and has a more beautiful appearance.

[0095] (2) The yoke and core column adopt a circular arc transition, which can further reduce the internal stress of the amorphous strip and reduce the damage to the amorphous strip during the winding process, thereby reducing the no-load loss of the amorphous strip. It can also reduce the trimming process during the stacking of the core cake and improve the stacking efficiency.

[0096] (3) It is made by winding. Compared with the traditional splicing method, it can reduce the number of internal seams and reduce the noise generated by the iron core seams. At the same time, the winding structure can make the connection between each layer of amorphous strip more compact, making the vibration space of the iron core during operation very small, thereby further reducing noise.

[0097] (4) The curing layer can improve the overall structural strength of the amorphous alloy three-dimensional coiled core and enhance its short-circuit resistance.

[0098] Example 3

[0099] This embodiment discloses a transformer, including an iron core, wherein the iron core adopts the amorphous alloy three-dimensional wound iron core described in Embodiment 2.

[0100] The transformer can be an oil-immersed transformer, a dry-type transformer, or other types of transformers. The capacity range of the transformer is 50kVA to 10000kVA.

[0101] In this embodiment, the transformer capacity is preferably 2500kVA, the corresponding arc edge R is preferably 2000mm, and the corresponding arc r is preferably 5mm.

[0102] The transformer in this embodiment uses the amorphous alloy three-dimensional wound core described in Embodiment 2. Therefore, it has the advantages of low no-load loss, low noise, and strong short-circuit resistance. Furthermore, since the core column is approximately cylindrical, the filling rate is high, which can reduce the amount of copper wire, transformer oil, and other materials used, thereby reducing production costs.

[0103] It is understood that the above description is merely a preferred embodiment of the present invention, and the present invention is not limited thereto. For those skilled in the art, various modifications and improvements can be made without departing from the spirit and essence of the present invention, and these modifications and improvements are also considered to be within the scope of protection of the present invention.

Claims

1. A method for manufacturing an amorphous alloy three-dimensional wound core, comprising: S1, the amorphous ribbon is wound into a core disc with a circular cross-section; S2, using the circular support square process, the iron core disc with a circular cross-section is supported from the inside out and formed into a frame-shaped iron core disc with a cross-section similar to a rectangle; S3, after stacking and solidifying the multiple iron core cakes obtained in step S2, a single-frame amorphous alloy iron core is obtained; S4. Three identical single-frame amorphous alloy iron cores are spliced ​​together in pairs to obtain amorphous alloy three-dimensional coiled iron cores. Each core disc has two first frame edges (3) and two second frame edges (4). The inner edge of the first frame edge is a straight edge, and the inner edge of the second frame edge is a rounded edge. The first frame edges are used to form the core column of the single-frame amorphous alloy core, and the second frame edges are used to form the yoke of the single-frame amorphous alloy core. The inner edges of the first frame of each layer of iron core disc are distributed in a stepped manner, forming the second outer stepped edge. The outer edges of the first frame of each layer of iron core disc are also distributed in a stepped manner, forming the splicing stepped edge and the first outer stepped edge. The cross-section of the core column is approximately semi-circular. The splicing step edge includes multiple first steps, the vertices of which are on the same straight line, which forms the diameter of the cross-section of the core column. The first outer step edge includes multiple second steps, and the second outer step edge includes multiple third steps. The vertices of each second step and each third step are on the same arc surface, which forms the semi-circle of the cross-section of the core column.

2. The method for manufacturing amorphous alloy three-dimensional wound core according to claim 1, characterized in that, After step S2, the method further includes: S201, the frame-shaped iron core cake is subjected to heat treatment annealing; The heat treatment annealing temperature is 300-400℃, and the heat treatment annealing time is 50-150min.

3. The method for manufacturing an amorphous alloy three-dimensional wound core according to claim 2, characterized in that, The heat treatment annealing process is carried out in a protective gas atmosphere, wherein the protective gas is nitrogen or an inert gas, and the heat treatment annealing process is carried out in a DC magnetic field environment.

4. The method for manufacturing an amorphous alloy three-dimensional wound core according to claim 1, characterized in that, The curing temperature in step S3 is 60-150℃, and the curing time is 60-120min.

5. An amorphous alloy three-dimensional wound core manufactured using the amorphous alloy three-dimensional wound core manufacturing method according to any one of claims 1-4, characterized in that, It includes three identical single-frame amorphous alloy iron cores (9), which are spliced ​​together in pairs and arranged in a triangular pattern; Each of the single-frame amorphous alloy cores comprises multiple layers of core discs (10) stacked together. The core discs are formed by using a circular support-square process to shape the core discs with a circular cross-section from the inside out into a frame-shaped core disc with a cross-sectional shape similar to a rectangle. Each layer of the core disc has two first frame edges (3) and two second frame edges (4), the first frame edges being used to form the core pillar of the single-frame amorphous alloy core, and the second frame edges being used to form the yoke of the single-frame amorphous alloy core. The inner edge of the first frame is a straight edge, and the inner edge of the second frame is a rounded edge, with the radius R of the rounded edge being: 500≤R≤3000mm; The cross-section of the core column is approximately semi-circular, and the semi-circular cross-section includes a splicing step edge (6), a first outer step edge (71), and a second outer step edge (72). The splicing step edge includes multiple first steps, and the vertices of each first step are on the same straight line, which constitutes the diameter of the cross-section of the core column; The first outer step edge includes multiple second steps, and the second outer step edge includes multiple third steps. The vertices of each second step and each third step are located on the same arc surface, which forms a semicircle of the cross-section of the core column.

6. The amorphous alloy three-dimensional wound core according to claim 5, characterized in that, The inner edges of the first frame and the inner edges of the second frame are connected by an arc with a radius r of 2 ≤ r ≤ 20 mm.

7. The amorphous alloy three-dimensional wound core according to claim 5, characterized in that, The three amorphous alloy cores are arranged in an equilateral triangle. The angle between the splicing surface used for pairwise splicing in each single-frame amorphous alloy core and its yoke is 30°. For two spliced ​​single-frame amorphous alloy iron cores, the vertex of the first step of one single-frame amorphous alloy iron core is connected to the vertex of the first step of the other single-frame amorphous alloy iron core.

8. The amorphous alloy three-dimensional wound core according to any one of claims 5-7, characterized in that, The amorphous alloy three-dimensional coiled core also includes an insulating component (8), which is disposed between the splicing surfaces of every two single-frame amorphous alloy cores.

9. A transformer, comprising an iron core, characterized in that, The core is an amorphous alloy three-dimensional coiled core as described in any one of claims 5-8.

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