A core lamination structure and method with high step-in and low step-out angles
By optimizing the core lamination structure and adopting a high-order stepping low-order exit angle design, the problem of magnetic flux flow obstruction caused by the air gap space inside the core was solved, thereby improving the magnetic circuit flow performance and working efficiency of the core.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- WUXI JULONG SILICON STEEL CO LTD
- Filing Date
- 2022-12-27
- Publication Date
- 2026-07-28
AI Technical Summary
In existing core lamination methods, as the number of steps increases, the air gap space formed inside the core obstructs the flow of magnetic flux, affecting the core's working efficiency. Theoretically, only 8 steps can be achieved.
A core lamination structure and method with high-order stepping and low-order exit angles is adopted. By designing the middle column, left column, right column, upper yoke, and lower yoke, and combining lateral and longitudinal stepping stacking, the number of exit angles is reduced and the magnetic circuit flow performance is optimized.
Reducing the exit angle with the same number of steps improves magnetic circuit flow performance, reduces magnetic flux flow resistance, and enhances the no-load performance and working efficiency of the iron core.
Smart Images
Figure CN116130217B_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of iron core lamination technology, specifically relating to an iron core lamination structure and method with high-order stepping and low-order exit angle. Background Technology
[0002] Currently, the joints of transformer core laminations have a significant impact on transformer performance, particularly on no-load loss, noise, overall mechanical strength, and short-circuit withstand capability. In traditional core lamination processes, regardless of core type or size, lamination is performed in the same manner: one layer is stacked before the next, with layers stacked sequentially. A perforated positioning method is typically used, stacking multiple cores as a group. The number of cores in each group is called the step number. The arrangement of cores in each group is as follows: using the first core as a reference, cores are stacked at fixed intervals using either lateral or longitudinal steps, ultimately forming one core group.
[0003] While this lamination method can improve the flux transfer performance of the magnetic circuit and the no-load performance of the core, thereby reducing the no-load performance of the transformer, the existing cores have triangular apexes at both ends. When the cores are stacked alternately, corner spaces composed of air gaps are formed on the inner side of the core. Since the magnetic reluctance of air is much greater than that of silicon steel sheets, this strongly hinders the flow of magnetic flux. Therefore, the more steps there are, the stronger the resistance becomes, severely affecting the core's operating efficiency. Consequently, as the number of steps increases, the rate of improvement in the core's magnetic flux performance gradually decreases, reaching its peak at 8 steps (see Critical induction: a key quantity of the optimization of transformer core operation). Therefore, theoretically, only 8 steps can be achieved. Summary of the Invention
[0004] To overcome the shortcomings of the prior art, the present invention aims to provide a core lamination structure and method with high-order stepping and low-order exit angle. The purpose is to solve the problem that in the conventional lamination method, as the number of steps increases, corners composed of air gap spaces are formed on the inner side of the core. Since the magnetic reluctance of air is much greater than that of silicon steel sheets, it will strongly hinder the flow of magnetic flux. The present invention forms a higher-order stepping based on 8 steps, and at the same time only forms corner spaces corresponding to 8 steps.
[0005] This invention is achieved through the following technical solution:
[0006] A core lamination structure and method with high-order stepping and low-order exit angle includes a central column, a left side column, a right side column, an upper yoke, and a lower yoke. The left side column and the right side column are disposed on the left and right sides of the central column, and the upper yoke and the lower yoke are disposed on the upper and lower sides of the central column. The central column, left side column, right side column, upper yoke, and lower yoke are all in contact with each other. Each of the central column, left side column, right side column, upper yoke, and lower yoke includes a plurality of silicon steel sheet units stacked sequentially. Each silicon steel sheet unit includes a first silicon steel sheet group and a second silicon steel sheet group that are symmetrically arranged. The first silicon steel sheet group and the second silicon steel sheet group are stacked in a symmetrical horizontal or vertical stepping manner, and the second silicon steel sheet group is disposed above the first silicon steel sheet group.
[0007] To optimize the above technical solution, the specific measures also include:
[0008] Furthermore, the upper and lower yoke plates are symmetrical to each other, and the left and right pillars are symmetrical to each other.
[0009] Furthermore, each of the silicon steel sheet units is provided with positioning holes.
[0010] Furthermore, the number of silicon steel sheets in the first silicon steel sheet group and the second silicon steel sheet group is equal and is an odd number.
[0011] Furthermore, the silicon steel sheet units corresponding to the middle column, upper yoke, and lower yoke are all stacked in a horizontal stepping manner, while the silicon steel sheet units corresponding to the left and right columns are all stacked in a vertical stepping manner.
[0012] Furthermore, the stacking interval distance of the lateral stepping setting is equal to the stacking interval distance of the longitudinal stepping setting.
[0013] Further, the lateral step stacking is as follows: the first silicon steel sheet group and the second silicon steel sheet group are stacked sequentially from bottom to top, the second silicon steel sheet group is stacked on top of the first silicon steel sheet group, the top silicon steel sheet of the first silicon steel sheet group and the top silicon steel sheet of the second silicon steel sheet group overlap each other, and several horizontally oriented protruding angles are formed at both ends of the silicon steel sheet unit; the longitudinal step stacking is as follows: the first silicon steel sheet group and the second silicon steel sheet group are stacked sequentially from bottom to top, the second silicon steel sheet group is stacked on top of the first silicon steel sheet group, the top silicon steel sheet of the first silicon steel sheet group and the top silicon steel sheet of the second silicon steel sheet group overlap each other, and several vertically oriented protruding angles are formed at both ends of the silicon steel sheet unit.
[0014] Furthermore, the number of protruding corners formed by the silicon steel sheet unit is less than the number of silicon steel sheets.
[0015] Furthermore, the uppermost silicon steel sheet in the first and second silicon steel sheet groups corresponding to the central column has symmetrical pointed ends at both ends. The upper end of the remaining silicon steel sheets in the first silicon steel sheet group is located on the left, and the lower end of the remaining silicon steel sheets in the first silicon steel sheet group is located on the right. The upper end of the remaining silicon steel sheets in the second silicon steel sheet group is located on the right, and the lower end of the remaining silicon steel sheets in the second silicon steel sheet group is located on the left. The size of each silicon steel sheet in the corresponding silicon steel sheet unit of the upper yoke, lower yoke, left column, and right column is the same.
[0016] A method for laminating iron cores with high-order stepping and low-order exit angle includes the following steps:
[0017] Each silicon steel sheet unit corresponding to the middle column, upper yoke, and lower yoke is divided into a first group and a second group on an average basis.
[0018] The first and second groups are stacked sequentially from bottom to top in a horizontal stepping manner, so that the top silicon steel sheet of the first silicon steel sheet group and the top silicon steel sheet of the second silicon steel sheet group overlap each other, forming several horizontally oriented protruding corners.
[0019] Each silicon steel sheet unit corresponding to the upper and lower yokes is divided into a first group and a second group on an average basis.
[0020] The first and second groups are stacked sequentially from bottom to top in a vertical stepping manner, so that the top silicon steel sheet of the first silicon steel sheet group and the top silicon steel sheet of the second silicon steel sheet group overlap each other, forming several vertically oriented protruding corners.
[0021] Using N pieces as a cycle, perform pre-stacking of the middle pillar, left pillar, right pillar, upper yoke piece, and lower yoke piece;
[0022] Using the pre-stacked upper yoke as the positioning reference, the pre-stacked middle column, left column, right column and lower yoke are stacked in sequence;
[0023] Based on the first layer of silicon steel sheet unit formed at the bottom, pre-stacked silicon steel sheet units with progressively larger sizes are stacked from bottom to top until the largest silicon steel sheet unit in the center layer is formed.
[0024] Using the largest silicon steel sheet unit in the central layer as the center of symmetry, silicon steel sheet units with progressively smaller sizes are stacked upwards until a symmetrical structure is formed.
[0025] The beneficial effects of this invention are:
[0026] This invention discloses a core lamination structure with high-order stepping and low-order exit angles. The arrangement of the cores in each layer is improved. Compared to the conventional method where each step corresponds to one exit angle, the lamination structure in this application can reduce one exit angle while maintaining the same number of steps. On the one hand, it allows for an increase in the number of steps under the same conditions, thereby improving the magnetic flux flow performance and the core's no-load performance. On the other hand, reducing the number of exit angles reduces the obstruction to magnetic flux flow caused by the increased corner space resulting from the increased number of steps, thus improving the core's working efficiency. Attached Figure Description
[0027] Figure 1 This is a schematic diagram of a core lamination structure with a high-order stepping and low-order exit angle according to the first embodiment of the present invention.
[0028] Figure 2 This is the present invention. Figure 1 A partial schematic diagram of the corner structure formed by the upper middle section and the right side column.
[0029] Figure 3 This is the present invention. Figure 1 A schematic diagram of the overall structure of the central column.
[0030] Figure 4 This is the present invention. Figure 3 A schematic diagram of the exploded structure of the central column.
[0031] Figure 5 This is the present invention. Figure 1 A schematic diagram of the overall structure of the left column in the middle.
[0032] Figure 6 This is the present invention. Figure 5 A schematic diagram of the exploded structure of the left column in the middle.
[0033] Figure description: Central column A, left column B, right column C, upper plate D, lower plate E, silicon steel sheet unit 10, first silicon steel sheet group 11, second silicon steel sheet group 12. Detailed Implementation
[0034] To clarify the technical solution and working principle of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.
[0035] First Embodiment
[0036] like Figure 1-6As shown, this embodiment of the invention provides a core lamination structure with a high-order stepping and low-order exit angle, including a central column A, a left column B, a right column C, an upper yoke D, and a lower yoke E. The left column B and the right column C are disposed on the left and right sides of the central column A, and the upper yoke D and the lower yoke E are disposed on the upper and lower sides of the central column A. The central column A, the left column B, the right column C, the upper yoke D, and the lower yoke E are all in contact with each other. The central column A, the left column B, the right column C, the upper yoke D, and the lower yoke E each include a plurality of silicon steel sheet units 10 stacked sequentially. Each silicon steel sheet unit 10 includes a first silicon steel sheet group 11 and a second silicon steel sheet group 12 that are symmetrically stacked. The first silicon steel sheet group 11 and the second silicon steel sheet group 12 are stacked in a symmetrical horizontal or vertical stepping manner, respectively. The second silicon steel sheet group 12 is disposed above the first silicon steel sheet group 11.
[0037] The silicon steel sheet units 10 corresponding to the middle column A, upper yoke D, and lower yoke E are all stacked in a horizontal stepping manner, while the silicon steel sheet units 10 corresponding to the left column B and right column C are stacked in a vertical stepping manner. Each silicon steel sheet unit is provided with positioning holes, which are used for positioning and assembly when the silicon steel sheet unit 10 is formed by stacking. The assembled upper and lower yokes are symmetrical to each other, and the left and right columns are symmetrical to each other. At the same time, equal-sized spaces are formed between the middle column A and the left column B, and between the middle column A and the right column C. These spaces are used to place the coil.
[0038] When the silicon steel sheet units 10 corresponding to the central column A, upper yoke D, and lower yoke E are stacked in a transverse step manner, the number of silicon steel sheets in each silicon steel sheet unit is equal and odd. The central column A has pointed ends, which are respectively inserted into the notches of the silicon steel sheets corresponding to the upper yoke and lower yoke, facilitating the corresponding splicing of the upper yoke D and lower yoke E with the central column A.
[0039] When the silicon steel sheet units 10 corresponding to the left column B and the right column C are stacked in a longitudinal stepping manner, the number of silicon steel sheets in each silicon steel sheet unit is also equal and odd. At the same time, the number is equal to the number of silicon steel sheets in the silicon steel sheet units corresponding to the middle column A, the upper yoke D, and the lower yoke E, which facilitates the splicing of the left column B and the right column C with the corresponding upper yoke D and lower yoke E.
[0040] During stacking, the lateral stepping stacking intervals corresponding to the middle column A, upper yoke D, and lower yoke E are equal to the longitudinal stepping stacking intervals corresponding to the left column B and right column C. The lateral stepping stacking is as follows: the first silicon steel sheet group 11 and the second silicon steel sheet group 12 are stacked sequentially from bottom to top, with the second silicon steel sheet group 12 stacked on top of the first silicon steel sheet group 11. The topmost silicon steel sheets of the first silicon steel sheet group 11 and the topmost silicon steel sheets of the second silicon steel sheet group 12 overlap each other. Each silicon steel sheet unit 10 has several horizontally oriented protruding angles at both ends. The longitudinal stepping stacking is as follows: the first silicon steel sheet group 11 and the second silicon steel sheet group 12 are stacked sequentially from bottom to top, with the second silicon steel sheet group 12 stacked on top of the first silicon steel sheet group 11. The topmost silicon steel sheets of the first silicon steel sheet group 11 and the topmost silicon steel sheets of the second silicon steel sheet group 12 overlap each other. Each silicon steel sheet unit 10 has several vertically oriented protruding angles at both ends. The final number of protruding corners in the stacked silicon steel sheet unit is less than the number of silicon steel sheets. Specifically, the number of protruding corners in the silicon steel sheet unit is one less than the number of silicon steel sheets.
[0041] Meanwhile, the uppermost silicon steel sheet in the first silicon steel sheet group 11 and the second silicon steel sheet group 12 corresponding to the central column A has symmetrical pointed ends at both ends. The upper end of the remaining silicon steel sheets in the first silicon steel sheet group 11 has its protruding angle on the left, and the lower end of the remaining silicon steel sheets in the first silicon steel sheet group 11 has its protruding angle on the right. The upper end of the remaining silicon steel sheets in the second silicon steel sheet group 12 has its protruding angle on the right, and the lower end of the remaining silicon steel sheets in the second silicon steel sheet group 12 has its protruding angle on the left. Among them, the silicon steel sheets in the silicon steel sheet units 10 corresponding to the upper yoke D, lower yoke E, left column B, and right column C are of the same size.
[0042] Second Embodiment
[0043] This embodiment also provides a method for laminating iron cores with high-order stepping and low-order exit angle, including the following steps:
[0044] Each silicon steel sheet unit corresponding to the middle column, upper yoke, and lower yoke is divided into a first group and a second group on an average basis.
[0045] The first and second groups are stacked sequentially from bottom to top in a horizontal stepping manner, so that the top silicon steel sheet of the first silicon steel sheet group and the top silicon steel sheet of the second silicon steel sheet group overlap each other, forming several horizontally oriented protruding corners.
[0046] Each silicon steel sheet unit corresponding to the upper and lower yokes is divided into a first group and a second group on an average basis.
[0047] The first and second groups are stacked sequentially from bottom to top in a vertical stepping manner, so that the top silicon steel sheet of the first silicon steel sheet group and the top silicon steel sheet of the second silicon steel sheet group overlap each other, forming several vertically oriented protruding corners.
[0048] Using N pieces as a cycle, perform pre-stacking of the middle pillar, left pillar, right pillar, upper yoke piece, and lower yoke piece;
[0049] Using the pre-stacked upper yoke as the positioning reference, the pre-stacked middle column, left column, right column and lower yoke are stacked in sequence;
[0050] Based on the first layer of silicon steel sheet unit formed at the bottom, pre-stacked silicon steel sheet units with progressively larger sizes are stacked from bottom to top until the largest silicon steel sheet unit in the center layer is formed.
[0051] Using the largest silicon steel sheet unit in the central layer as the center of symmetry, silicon steel sheet units with progressively smaller sizes are stacked upwards until a symmetrical structure is formed.
[0052] like Figure 1-6 As shown, the process of stacking the central column is explained using an 8-step method as an example:
[0053] During lamination, the eight silicon steel sheets are first divided into two groups of four. The first group is stacked sequentially from left to right with a 1-degree interval, resulting in the order 1, 2, 3, 4. Simultaneously, the second group is stacked sequentially from right to left with a 1-degree interval, resulting in the order 8, 7, 6, 5. At this point, the fourth and eighth silicon steel sheets overlap, with a gap of three sheets in between. Because the fourth and eighth sheets overlap, seven exit corners are formed. Reducing one exit corner while maintaining the same number of steps allows for an increase in the number of steps, improving magnetic flux flow and core no-load performance. Furthermore, reducing the number of exit corners minimizes the obstruction to magnetic flux flow caused by the increased corner space due to the increased number of steps, thus improving the core's efficiency.
[0054] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should be considered within the scope of protection of the present invention.
Claims
1. A core lamination structure with high-order stepping and low-order exit angle, characterized in that: The system includes a central column, a left column, a right column, an upper yoke, and a lower yoke. The left and right columns are positioned on the left and right sides of the central column, while the upper and lower yokes are positioned on the upper and lower sides of the central column. The central column, left column, and right column are all in contact with the upper and lower yokes. Each of the central column, left column, right column, upper yoke, and lower yoke comprises several sequentially stacked silicon steel sheet units. Each silicon steel sheet unit includes a first and a second symmetrical group of silicon steel sheets. The first and second groups of silicon steel sheets are stacked in a symmetrical horizontal or vertical stepping pattern, with the second group of silicon steel sheets positioned above the first group. The silicon steel sheet units corresponding to the central column, upper yoke, and lower yoke are stacked in a horizontal stepping pattern, while the silicon steel sheet units corresponding to the left and right columns are stacked in a vertical stepping pattern. The horizontal stepping stacking consists of: the first silicon steel sheet group and the second silicon steel sheet group... The silicon steel sheet groups are stacked sequentially from bottom to top, with the second silicon steel sheet group stacked on top of the first silicon steel sheet group. The top silicon steel sheet of the first silicon steel sheet group and the top silicon steel sheet of the second silicon steel sheet group overlap each other. Each silicon steel sheet unit forms several horizontally oriented protruding corners at both ends. The longitudinal step stacking is as follows: the first silicon steel sheet group and the second silicon steel sheet group are stacked sequentially from bottom to top, with the second silicon steel sheet group stacked on top of the first silicon steel sheet group. The top silicon steel sheet of the first silicon steel sheet group and the top silicon steel sheet of the second silicon steel sheet group overlap each other. Each silicon steel sheet unit forms several vertically oriented protruding corners on both sides. The number of silicon steel sheets in the first silicon steel sheet group and the second silicon steel sheet group is equal and odd. The stacking interval distance of the lateral step stacking is equal to the stacking interval distance of the longitudinal step stacking. The number of protruding corners formed by each silicon steel sheet unit is less than the number of silicon steel sheets.
2. The core lamination structure with high-order stepping and low-order exit angle according to claim 1, characterized in that: The upper and lower yoke plates are symmetrical to each other, and the left and right pillars are symmetrical to each other.
3. The core lamination structure with high-order stepping and low-order exit angle according to claim 1, characterized in that: Each of the silicon steel sheet units is provided with positioning holes.
4. The core lamination structure with high-order stepping and low-order exit angle according to claim 1, characterized in that: The uppermost silicon steel sheet in the first and second silicon steel sheet groups corresponding to the central column has symmetrical pointed ends at both ends. The upper end of the remaining silicon steel sheets in the first silicon steel sheet group corresponding to the central column is located on the left, and the lower end is located on the right. The upper end of the remaining silicon steel sheets in the second silicon steel sheet group corresponding to the central column is located on the right, and the lower end is located on the left. The size of each silicon steel sheet in the silicon steel sheet unit corresponding to the upper yoke, lower yoke, left column, and right column is the same.
5. A lamination method for a core lamination structure with a high-order stepping and low-order exit angle as described in claim 1, characterized in that, Includes the following steps: Each silicon steel sheet unit corresponding to the middle column, upper yoke, and lower yoke is equally divided into a first group and a second group that are symmetrical to each other. The first and second groups are stacked sequentially from bottom to top in a horizontal stepping manner, so that the top silicon steel sheet of the first silicon steel sheet group and the top silicon steel sheet of the second silicon steel sheet group overlap each other, forming several horizontally oriented protruding corners. Each silicon steel sheet unit corresponding to the upper and lower yokes is divided into a first group and a second group that are symmetrical to each other. The first and second groups are stacked sequentially from bottom to top in a vertical stepping manner, so that the top silicon steel sheet of the first silicon steel sheet group and the top silicon steel sheet of the second silicon steel sheet group overlap each other, forming several vertically oriented protruding corners. Using N pieces as a cycle, perform pre-stacking of the middle pillar, left pillar, right pillar, upper yoke piece, and lower yoke piece; Using the pre-stacked upper yoke as the positioning reference, the pre-stacked middle column, left column, right column and lower yoke are stacked in sequence; Based on the first layer of silicon steel sheet unit formed at the bottom, pre-stacked silicon steel sheet units with progressively larger sizes are stacked from bottom to top until the largest silicon steel sheet unit in the center layer is formed. Using the largest silicon steel sheet unit in the central layer as the center of symmetry, silicon steel sheet units with progressively smaller sizes are stacked upwards until a symmetrical structure is formed.