A three-dimensional volume core transformer combined amorphous core

Abstract

The application discloses a combined amorphous core of a three-dimensional roll core transformer and belongs to the field of transformers. The combined amorphous core of the application divides a single-frame core body into at least two core frames which are rolled from amorphous alloy strips and have spliced end faces. The amorphous core of the three-dimensional roll core transformer is formed by splicing and combining the core frames, is no longer limited by the width specifications of the existing amorphous alloy strips, and can be made from the existing amorphous alloy strips with different widths to produce amorphous cores of three-dimensional roll core transformers with different capacities. Moreover, the end faces of the core frames which are independently rolled are spliced to form the single-frame core body, and the splicing and combining structure and the manufacturing process are simpler. Meanwhile, the core column section is designed in a non-circular shape, the amorphous alloy strips are conveniently slitted and rolled, the material utilization rate is high, the utilization rate of the core material is 100%, and a large amount of amorphous alloy strip cost is saved.

Description

[0001] The present application claims priority to Chinese Patent Application No. 202123009752.9 entitled "A combined amorphous core of a three-dimensional wound core transformer" filed on December 02, 2021. TECHNICAL FIELD

[0002] The present application relates to a transformer core structure, more particularly, to a combined amorphous core of a three-dimensional wound core transformer. BACKGROUND

[0003] The triangular three-dimensional wound core transformer is a new structure of transformer, which creatively reforms the laminated magnetic circuit structure and three-phase layout of traditional transformer, optimizes the performance of the product, and is more and more recognized for its material saving and energy saving advantages. The two core components are triangular three-dimensional wound core and high-low voltage coil. The common high-low voltage coil is a circular structure. In order to match the shape of the coil, the core column section of the triangular three-dimensional wound core is also set to a circular or polygonal structure close to a circle to improve the performance of the transformer. However, the disadvantage of this approach is that the wound core is difficult to manufacture and consumes a lot of materials, which prevents the material saving and energy saving advantages of the triangular three-dimensional wound core transformer from being further expanded.

[0004] In order to solve the above problems existing in the core and coil of the existing triangular three-dimensional wound core transformer, Chinese Patent No. ZL201720159181.1 discloses "a triangular three-dimensional wound core transformer core and coil", which includes three single frame cores that are 60° apart from each other. The single frame core is wound or folded by an iron core sheet with a joint. The wide iron core sheet is arranged on the inner side of the single frame core window, and the small piece width iron core sheet is arranged on the outer side of the single frame core window, and the piece width of the iron core sheet gradually decreases from the inner side to the outer side of the single frame core window. It breaks the limitations of the traditional core and coil structure. Under the same core section and the same core window size, the weight of the core is lighter, which greatly saves the core material. Furthermore, the structure of the core is simplified, and the manufacturing process of the core is enhanced.

[0005] With the improvement of the performance requirements of transformer and the maturity of amorphous alloy transformer technology, the triangular three-dimensional winding transformer is also developing towards the direction of amorphous alloy core, in order to reduce the loss of transformer and improve the energy saving of transformer. Due to the instability of the performance of wide amorphous alloy strip, at present, the amorphous alloy strip only has the width specifications of 120mm, 142mm, 170mm and 213mm. Because of the limitation of the width of amorphous alloy strip, on the one hand, the capacity of triangular three-dimensional winding transformer is limited, and it is difficult to be applied to large-capacity amorphous alloy transformer; on the other hand, the material loss is large when the above-mentioned specifications of amorphous alloy strip are used to make the core, which increases the cost of core material. In view of the problem of limited width of amorphous alloy strip, the Chinese patent No. ZL201510678304.8 discloses a "three-dimensional winding core of amorphous alloy transformer", which proposes a technical scheme, the three-dimensional winding core of amorphous alloy transformer, comprising a core column combination, an upper iron yoke arranged at the upper end of the core column combination and a lower iron yoke arranged at the lower end of the core column combination; the core column combination comprises a plurality of core columns, each core column comprises a plurality of amorphous alloy strips, each amorphous alloy strip is a cylindrical strip, and the adjacent amorphous alloy strips are in surface contact and closely fit; a plurality of amorphous alloy strips form a cylindrical core column, which is formed in the following way: using the existing width specification of amorphous alloy strip to cut into amorphous alloy strips of any shape, closely fitting and arranging the cut amorphous alloy strips to form a cylindrical core column; by using a plurality of amorphous alloy strips to form a core column, a core column of any size is obtained. The patent application uses amorphous alloy strips of different specifications to form a core column, which can use existing specifications of amorphous alloy strip to make core columns of various sizes, but the core column combination structure and manufacturing process are relatively complex, and the core column needs to be assembled with the upper and lower iron yokes to form a three-dimensional winding core, which makes the structure of the three-dimensional winding core of amorphous alloy transformer more complex. SUMMARY

[0006] 1. Technical problems to be solved by the invention

[0007] The purpose of the present application is to solve the problem that the amorphous core of the three-dimensional wound core transformer is difficult to be applied to large capacity transformers due to the limitation of the width of the amorphous alloy strip, and the combination structure and manufacturing process of the amorphous three-dimensional wound core transformer are complex, and a combined amorphous core of a three-dimensional wound core transformer is provided.

[0008] 2. Technical scheme

[0009] To achieve the above purpose, the technical scheme provided by the present application is:

[0010] The combined amorphous core of the three-dimensional wound core transformer of the present application comprises a single-frame core body, which is combined by a first core frame and a second core frame in an end face splicing manner, and the first core frame and the second core frame are both frame body structures with splicing end faces, which are wound from amorphous alloy strips.

[0011] Further, the single-frame core body further comprises at least one third core frame, which is a frame body structure with splicing end faces at both ends, wound from an amorphous alloy strip, and the third core frame is clamped between the first core frame and the second core frame.

[0012] Further, it comprises three single-frame core bodies spliced at an angle of 60° to each other, and the adjacent single-frame core bodies are spliced to form a core column capable of winding or assembling high and low voltage coils, thereby forming an amorphous core of a three-dimensional wound core transformer.

[0013] Further, the core column cross section of the first core frame is a right trapezoid, and the core column cross section of the second core frame is a rectangle with a bevel angle on the outer side of the core.

[0014] Further, in the core column cross section of the first core frame, the acute angle of the right trapezoidal section is 60°; in the core column cross section of the second core frame, the bevel angle of the rectangular section corresponds to a bevel plane which is perpendicular to the splicing surface of the adjacent two single-frame core bodies.

[0015] Further, the core column cross section shape of the third iron core frame arranged between the first and second iron core frames is rectangular.

[0016] Further, the first, second and third iron core frames are all rolled from existing non-crystalline alloy strip material, wherein the first iron core frame is rolled from trapezoidal material strip cut from non-crystalline alloy strip material or segmented and then rolled from trapezoidal material strip cut from non-crystalline alloy strip material; the second iron core frame is divided into an inner frame with a rectangular core column cross section shape and an outer frame with a right-angled trapezoidal core column cross section shape, the inner frame is rolled from rectangular material strip cut from non-crystalline alloy strip material or segmented and then rolled from rectangular material strip cut from non-crystalline alloy strip material, and the outer frame is tightly rolled on the inner frame from trapezoidal material strip cut from non-crystalline alloy strip material or segmented and then tightly rolled on the inner frame from trapezoidal material strip cut from non-crystalline alloy strip material; and the third iron core frame is rolled from rectangular material strip cut from non-crystalline alloy strip material or segmented and then rolled from rectangular material strip cut from non-crystalline alloy strip material.

[0017] 3. Beneficial effects

[0018] Compared with the prior art, the technical scheme provided by the present application has the following beneficial effects:

[0019] (1) The three-dimensional roll iron core transformer combined non-crystalline core of the present application comprises a single-frame core body, which is combined by a first iron core frame and a second iron core frame in an end face splicing manner, and the first and second iron core frames are both frame structures with splicing end faces and are rolled from non-crystalline alloy strip material; the single-frame core body is divided into at least two iron core frames with splicing end faces and rolled from non-crystalline alloy strip material, and the non-crystalline core of the three-dimensional roll iron core transformer is formed by splicing and combining the iron core frames, so that the non-crystalline core of the three-dimensional roll iron core transformer is not limited by the existing non-crystalline alloy strip material width specification, and different capacity three-dimensional roll iron core transformers can be made from the existing non-crystalline alloy strip material with a width specification; and the end faces of the independently rolled iron core frames are spliced to form the single-frame core body, so that the splicing and combining structure and the manufacturing process are simpler.

[0020] (2) The three-dimensional roll iron core transformer combined non-crystalline core of the present application comprises three single-frame core bodies spliced at an angle of 60° to each other, the adjacent single-frame core bodies are spliced to form core columns capable of winding or assembling high and low voltage coils, and the non-crystalline core of the three-dimensional roll iron core transformer is formed, so that the non-crystalline alloy core is applied in the three-dimensional roll iron core transformer, the loss of the three-dimensional roll iron core transformer is reduced, and the energy saving of the three-dimensional roll iron core transformer is further improved.

[0021] (3) The combined amorphous core of the three-dimensional wound core transformer of the present application, the core column cross section shape of the first core frame is a right trapezoid, the core column cross section shape of the second core frame is a rectangle with a bevel angle on the outer side of the core; in the core column cross section of the first core frame, the acute angle of the right trapezoid section is 60°, in the core column cross section of the second core frame, the bevel angle corresponding to the inclined plane of the rectangular section is perpendicular to the splicing surface of the adjacent two single frame core bodies; the core column cross section shape of the third core frame arranged between the first core frame and the second core frame is a rectangle; the non-circular core column section design is adopted, the amorphous alloy strip is convenient to cut and wind, the material utilization rate is high, the core material utilization of 100% is beneficial to realize, and a large amount of amorphous alloy strip cost is saved;

[0022] (4) The combined amorphous core of the three-dimensional wound core transformer of the present application not only improves the material utilization rate of the amorphous alloy strip, but also optimizes the manufacturing process of the three-dimensional transformer amorphous core, so that the cross section shape forming of the amorphous core is more simple and convenient, and the performance of the transformer can be further improved. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 It is a top view structural schematic diagram of the combined amorphous core of the three-dimensional wound core transformer of the present application;

[0024] Figure 2 It is a structural schematic diagram of the single frame core body in the present application;

[0025] Figure 3 It is a structural schematic diagram of the combined amorphous core in the three-dimensional wound core transformer of the present application;

[0026] Figure 4 It is a first combined structure schematic diagram of the core column cross section of the single frame core body in the present application;

[0027] Figure 5 It is a second combined structure schematic diagram of the core column cross section of the single frame core body in the present application;

[0028] Figure 6 It is a core column cross section size and strip cutting size marking diagram of the single frame core body in the present application;

[0029] Figure 7 It is a core column cross section size and strip cutting size marking diagram of the present integrated single frame core body.

[0030] Explanation of the reference numerals in the schematic diagram:

[0031] 1, single frame core body; 1-1, first core frame; 1-1A, splicing surface; 1-2, second core frame; 1-2A, inclined plane; 1-3, third core frame; 2, high and low voltage coil. DETAILED DESCRIPTION

[0032] For a further understanding of the present application, reference will be made to the following description taken in conjunction with the accompanying drawings and examples.

[0033] [Example 1]

[0034] In combination Figure 1 and Figure 2 As shown in the drawings, the combined amorphous core of the three-dimensional wound core transformer of the present embodiment comprises a single-frame core body 1 which is combined by a first core frame 1-1 and a second core frame 1-2 in an end-face splicing manner. Both the first core frame 1-1 and the second core frame 1-2 are frame body structures wound by amorphous alloy strips and have splicing end faces. That is, the single-frame core body 1 is divided into at least two independent frames along its transverse direction, each of which is wound by amorphous alloy strips. The single-frame core body 1 is formed by splicing and combining the independent frames. In this way, the three-dimensional wound core transformer amorphous core of different capacities can be made by using the existing amorphous alloy strips without being limited by the width specifications of the existing amorphous alloy strips. Moreover, the end faces of the independent frames are spliced to form the single-frame core body, and the splicing and combining structure and manufacturing process are simpler.

[0035] As shown in the drawings Figure 1 , Figure 2 and Figure 4 In the present embodiment, the single-frame core body 1 is combined by two core frames, i.e., the first core frame 1-1 and the second core frame 1-2. Further in combination with Figure 3 As shown in the drawings, the combined amorphous core of the three-dimensional wound core transformer of the present embodiment comprises three single-frame core bodies 1 which are spliced at an angle of 60° to each other. The adjacent single-frame core bodies 1 are spliced to form a core column in which high-voltage and low-voltage coils 2 can be wound or assembled, thereby constituting an amorphous core of a three-dimensional wound core transformer. The high-voltage and low-voltage coils 2 are wound according to the cross-sectional shape of the core column formed by splicing the adjacent single-frame core bodies 1. In the three-dimensional wound core transformer, the application of the amorphous alloy core is realized, the loss of the three-dimensional wound core transformer is reduced, and the energy-saving property of the three-dimensional wound core transformer is further improved. Further in combination with Figure 4 and Figure 6As shown, in the present embodiment, the core column cross-sectional shape of the first core frame 1-1 is a right trapezoid, and the core column cross-sectional shape of the second core frame 1-2 is a rectangle with a bevel angle on the outer side of the core. In the core column cross-sectional shape of the first core frame 1-1, the acute angle of the right trapezoidal section is 60°; in the core column cross-sectional shape of the second core frame 1-2, the bevel angle of the rectangular section corresponds to a bevel plane 1-2A which is perpendicular to the splicing surface 1-1A of the adjacent two single-frame core bodies 1, that is, the angle between the bevel plane 1-2A and the middle window side wall of the second core frame 1-2 is 30°, so that after the adjacent single-frame core bodies 1 are spliced with the splicing surface 1-1A, the bevel planes 1-2A on the two single-frame core bodies 1 can be located on the same plane, which is conducive to close cooperation with the high-low voltage coil 2. The non-circular core column cross-sectional design is convenient for cutting and rolling of amorphous alloy strips, has high material utilization rate, is conducive to achieving 100% utilization of core materials, and saves a large amount of amorphous alloy strip cost.

[0036] In particular, in the present embodiment, the first core frame 1-1 and the second core frame 1-2 are both rolled after being cut from existing amorphous alloy strips with a certain width. Figure 4 As shown, the first core frame 1-1 is rolled from the trapezoidal material strip cut from the amorphous alloy strip or is rolled after being segmented from the trapezoidal material strip cut from the amorphous alloy strip; the second core frame 1-2 is divided into an inner frame with a rectangular cross-sectional shape of the core column part and an outer frame with a right trapezoidal cross-sectional shape of the core column part, the inner frame is Figure 4 the core column cross-sectional part in reference numeral ②, and the outer frame is Figure 4 the core column cross-sectional part in reference numeral ③, the inner frame is rolled from the rectangular material strip cut from the amorphous alloy strip or is rolled after being segmented from the rectangular material strip cut from the amorphous alloy strip, and the outer frame is tightly rolled on the inner frame from the trapezoidal material strip cut from the amorphous alloy strip or is tightly rolled on the inner frame after being segmented from the trapezoidal material strip cut from the amorphous alloy strip. When the material strip cut from the amorphous alloy strip is rolled, the single-frame core body 1 is a closed structure, and when the material strip cut from the amorphous alloy strip is segmented and then rolled, the single-frame core body 1 is an open structure.

[0037] As shown in the core column cross-sectional shape of the single-frame core body 1, Figure 4 and Figure 6 the core column cross-sectional shape of the single-frame core body 1, the determination of the cutting size of the amorphous alloy strip and the calculation method of the core column cross-sectional area are described respectively. The standard specifications of the existing amorphous alloy strip are 120 mm, 142 mm, 170 mm and 213 mm.

[0038] Serial number Standard strip gauge Slitting into equal parts Slitting width Large head Small head ① X1 N1 a1 H1 A3 ② X2 N2 a2 H2 H2 ③ X3 N3 a3 H2 A4

[0039] Figure 4The strip cutting sizes of the three cross-sectional areas ① to ③ are shown in the above table, wherein the straight-angle trapezoidal strip is formed by equally dividing the standard strip into rectangular strips and then obliquely cutting the rectangular strips along the length direction of the strip, and thus the cutting width thereof = big head + small head, and X1, X2, X3, N1, N2, N3 in the above table are artificially determined. Then:

[0040] a1 = X1 / N1; a2 = X2 / N2; a3 = X3 / N3;

[0041] As shown in Figure 6 , B1 is a value artificially determined according to the magnetic density requirement of the core design, and the calculation relationship of the strip cutting sizes A1 to A5, H1 to H2 and B2 is as follows:

[0042] A1 = B1 / √3; A2 = A5 / 3; A3 = (a1-A1-A2)) / 2; A4 = a3-H2; A5 = H2-A4;

[0043] B2 = A2×√3; H1 = a1-A3; H2 = a2 (the cross-sectional area ② is rectangular, and can be directly coiled from the rectangular strip, and thus H2 can be directly cut from the standard strip);

[0044] As shown in Figure 6 , the areas of the three cross-sectional areas ① to ③ of the core column are as follows:

[0045] S1 = (A1+A2+A3+A3)×(B1+B2) / 2;

[0046] S2 = (A4+A5)×B1;

[0047] S3 = (A4+A4+A5)×B2 / 2;

[0048] The effective cross-sectional area of the core = (S1+S2+S3)×K1, wherein K1 is the lamination coefficient corresponding to the material.

[0049] The existing integrated single-frame core body design shown in Figure 7 requires two pieces of strip to be used to coil two trapezoidal core column cross sections, the width of the strip 1 = H+A6, and the width of the strip 2 = A6+A7, and the standard amorphous alloy strip cannot meet the design requirement, which seriously affects the utilization rate of the strip, and the forming process is poor.

[0050] [Example 2]

[0051] The combined amorphous core of the three-dimensional coiled core transformer of the present embodiment has the same basic structure and design principle as that of Example 1, and the difference is that:

[0052] As shown in Figure 5As shown, in the embodiment, the single-frame core body 1 further comprises at least one third core frame 1-3, which is a frame structure having spliced end faces at both ends and is rolled from amorphous alloy strip, and the third core frame 1-3 is clamped between the first core frame 1-1 and the second core frame 1-2. The core column cross-sectional shape of the third core frame 1-3 arranged between the first core frame 1-1 and the second core frame 1-2 is rectangular. The third core frame 1-3 is rolled from a rectangular material band cut from amorphous alloy strip or is segmented and then rolled from a rectangular material band cut from amorphous alloy strip. For a large-capacity transformer, the effective cross-sectional area of the core column can be increased by adding the third core frame 1-3.

[0053] The three-dimensional wound core transformer combined amorphous core of the present application divides the single-frame core body into at least two core frames rolled from amorphous alloy strip and having spliced end faces, and forms the amorphous core of the three-dimensional wound core transformer by splicing and combining the core frames, so that the three-dimensional wound core transformer amorphous core of different capacities can be made from amorphous alloy strip of existing width specifications without being limited by the width specifications of existing amorphous alloy strip. Moreover, the single-frame core body is formed by splicing the end faces of the core frames independently rolled, so that the splicing and combining structure and the manufacturing process are simpler. Meanwhile, the non-circular core column cross-sectional design facilitates the cutting and rolling of the amorphous alloy strip, has high material utilization, is conducive to achieving 100% utilization of core material, and saves a large amount of amorphous alloy strip cost.

[0054] In summary, the three-dimensional wound core transformer combined amorphous core of the present application not only improves the material utilization of amorphous alloy strip, but also optimizes the manufacturing process of the three-dimensional transformer amorphous core, makes the cross-sectional shape forming of the amorphous core simpler and more convenient, and further improves the performance of the transformer.

[0055] The above describes the present application and its embodiments in a schematic manner, which is not restrictive, and the embodiments shown in the drawings are only one of the embodiments of the present application, and the actual structure is not limited thereto. Therefore, if a person skilled in the art is inspired thereby, without departing from the purpose of the present application, designs a similar structure and embodiment without creativity, which should belong to the protection scope of the present application.

Claims

1. A three-dimensional volume core transformer combined amorphous core comprising a single frame core body (1), characterized in that: The single-frame core body (1) comprises a first core frame (1-1), a second core frame (1-2) and a third core frame (1-3), the first core frame (1-1), the second core frame (1-2) and the third core frame (1-3) are independent frame bodies with spliced end faces and are rolled from amorphous alloy strips; the first core frame (1-1), the second core frame (1-2) and the third core frame (1-3) are spliced and combined in a direction perpendicular to the window of the frame body to form the single-frame core body (1); the third core frame (1-3) is clamped between the first core frame (1-1) and the second core frame (1-2); the core column cross section shape of the first core frame (1-1) is a right trapezoid, the core column cross section shape of the second core frame (1-2) is a rectangle with a bevel angle on the outer side of the core; in the core column cross section of the first core frame (1-1), the acute angle of the right trapezoidal section is 60°; in the core column cross section of the second core frame (1-2), the bevel angle of the rectangular section corresponds to a bevel plane (1-2A) which is perpendicular to the splicing surface (1-1A) of the adjacent two single-frame core bodies (1); the core column cross section shape of the third core frame (1-3) arranged between the first core frame (1-1) and the second core frame (1-2) is a rectangle; after the adjacent single-frame core bodies (1) are spliced with the splicing surface (1-1A), the bevel planes (1-2A) on the two single-frame core bodies (1) are located on the same plane.

2. A three-dimensional volume wound core transformer combined amorphous core according to claim 1, characterized in that: The single-frame core body (1) comprises three single-frame core bodies (1) which are spliced at an angle of 60°, the adjacent single-frame core bodies (1) are spliced to form core columns capable of winding or assembling high-low voltage coils (2), and the amorphous core of the triangular three-dimensional wound core transformer is formed.

3. The combined amorphous core of a three-dimensional volume core transformer according to claim 2, characterized in that: The first core frame (1-1), the second core frame (1-2) and the third core frame (1-3) are all rolled from amorphous alloy strips after slitting, wherein: the first core frame (1-1) is rolled from a trapezoidal material strip after slitting or is rolled from a segmented trapezoidal material strip after slitting; the second core frame (1-2) is divided into an inner frame with a rectangular cross section and an outer frame with a right trapezoidal cross section, the inner frame is rolled from a rectangular material strip after slitting or is rolled from a segmented rectangular material strip after slitting, and the outer frame is tightly rolled from a trapezoidal material strip after slitting outside the inner frame or is tightly rolled from a segmented trapezoidal material strip after slitting outside the inner frame; the third core frame (1-3) is rolled from a rectangular material strip after slitting or is rolled from a segmented rectangular material strip after slitting.

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