Low-angle high-order longitudinal stepping core lamination structure and method

Abstract

The application discloses a low-angle high-order longitudinal stepping iron core lamination structure, which comprises a middle column, left side columns, right side columns, upper yoke sheets and lower yoke sheets, the left side columns and the right side columns are arranged on the left and right sides of the middle column, the upper yoke sheets and the lower yoke sheets are arranged on the upper and lower sides of the middle column, the middle column, the left side columns, the right side columns, the upper yoke sheets and the lower yoke sheets are all in contact connection, the middle column, the left side columns, the right side columns, the upper yoke sheets and the lower yoke sheets all comprise a plurality of silicon steel sheet units which are sequentially stacked, each silicon steel sheet unit comprises a first silicon steel sheet group and a second silicon steel sheet group, the first silicon steel sheet group and the second silicon steel sheet group comprise a plurality of silicon steel sheets which are sequentially stacked in opposite directions, and the second silicon steel sheet group is arranged above the first silicon steel sheet group. The application adopts a full longitudinal stepping stacking mode, reduces the number of angles, and improves the stacking efficiency and accuracy.

Description

Technical Field

[0001] This invention belongs to the field of iron core lamination technology, specifically relating to a high-order longitudinal stepping iron core lamination structure and method with low out-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. Typically, multiple cores are stacked as a group, and 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 flow 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, as the number of steps increases, the magnetic flux resistance also increases, and the rate of improvement in the core's magnetic flux performance gradually decreases. When a certain number of steps is exceeded, it will seriously affect the core's operating efficiency. Thus, as the number of steps increases, it reaches 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 high-order longitudinal stepping core lamination structure and method with a low exit angle, which addresses the following technical problems:

[0005] In existing technologies, conventional laminated structures form corners that are the same as the number of steps. These corners are composed of air gaps and are distributed on the inner side of the iron core. The corners strongly impede the flow of magnetic flux, so reaching 8 steps is the peak, and it is impossible to achieve a higher number of steps.

[0006] This invention is achieved through the following technical solution:

[0007] A high-order longitudinally stepped iron core lamination structure with a low outward 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, the left side column, the right side column, the upper yoke, and the lower yoke are all in contact with each other. Each of the central column, the left side column, the right side column, the upper yoke, and the 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. The first silicon steel sheet group and the second silicon steel sheet group include a plurality of silicon steel sheets stacked longitudinally in opposite directions. The second silicon steel sheet group is disposed above the first silicon steel sheet group.

[0008] To optimize the above technical solution, the specific measures also include:

[0009] Furthermore, the stacking interval between the first silicon steel sheet group and the second silicon steel sheet group is equal.

[0010] Furthermore, the uppermost silicon steel sheet of the first silicon steel sheet group overlaps with the uppermost silicon steel sheet of the second silicon steel sheet group but does not contact each other.

[0011] Furthermore, the first silicon steel sheet group and the second silicon steel sheet group corresponding to the middle column, left column, right column, upper yoke and lower yoke are stacked sequentially.

[0012] Furthermore, the two ends of the central column are provided with symmetrical sharp corners, the middle of the upper yoke is provided with a triangular notch one, and the middle of the lower yoke is provided with a triangular notch two, and the triangular notch one and the triangular notch two are respectively connected to the sharp corners.

[0013] Furthermore, the triangular notch one corresponding to the first silicon steel sheet group in the upper yoke gradually decreases in the stacking order, the triangular notch one corresponding to the second silicon steel sheet group in the upper yoke gradually increases in the stacking order, the triangular notch two corresponding to the first silicon steel sheet group in the lower yoke gradually increases in the stacking order, and the triangular notch two corresponding to the second silicon steel sheet group in the lower yoke gradually decreases in the stacking order. The triangular notches one and two that are in contact with each other at the sharp corner, the first silicon steel sheet group, and the second silicon steel sheet group have the same size.

[0014] Furthermore, each of the silicon steel sheets is provided with positioning holes, and the multiple positioning holes in each silicon steel sheet unit overlap with each other.

[0015] Furthermore, the exit angles formed by the first silicon steel sheet group and the second silicon steel sheet group within the left column, right column, upper yoke, and lower yoke are in opposite positions, and the size of the exit angles formed by the first silicon steel sheet group and the second silicon steel sheet group within the left column, right column, upper yoke, and lower yoke gradually decreases to zero along the stacking sequence.

[0016] Furthermore, the number of protruding corners formed by the silicon steel sheet unit is less than the number of silicon steel sheets.

[0017] A method for stacking high-order longitudinally stepping iron cores with low exit angles includes the following steps:

[0018] Each silicon steel sheet unit corresponding to the middle column, left column, right column, upper yoke, and lower yoke is equally divided into the first silicon steel sheet group and the second silicon steel sheet group.

[0019] The first silicon steel sheet group and the second silicon steel sheet group are stacked longitudinally in opposite directions to form a sequential arrangement structure, such that the uppermost silicon steel sheet of the first silicon steel sheet group and the lowermost silicon steel sheet of the second silicon steel sheet group overlap but do not touch each other.

[0020] Using N pieces as a cycle, perform pre-stacking of the middle pillar, left pillar, right pillar, upper yoke piece, and lower yoke piece;

[0021] 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;

[0022] 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.

[0023] 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.

[0024] The beneficial effects of this invention are:

[0025] This invention discloses a high-order longitudinal stepping core lamination structure with a low exit angle. It adopts a full longitudinal stepping stacking method and uses positioning holes for positioning, which improves the stacking efficiency and accuracy.

[0026] The silicon steel sheet unit is divided into two groups and stacked in a certain direction. At the same time, the silicon steel sheets in contact with each other in the two groups overlap, thereby reducing one exit angle at the current step number. This reduces the increase in corner space caused by the increase in the number of steps, reduces the obstruction to the flow of magnetic flux, and can further increase the number of steps, thereby improving the flow performance of the magnetic circuit and the no-load performance of the iron core. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of a high-order longitudinal stepping core lamination structure with a low 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 yoke and the right column.

[0029] Figure 3 This is the present invention. Figure 1 A schematic diagram of the exploded structure of the upper and middle yoke plates.

[0030] Figure 4 This is the present invention. Figure 3 A schematic diagram of the overall structure of the upper and middle yoke plates.

[0031] Figure 5 This is the present invention. Figure 1 A schematic diagram of the exploded structure of the left column in the middle.

[0032] Figure 6 This is the present invention. Figure 5 A schematic diagram of the overall structure of the left column in the middle.

[0033] Figure description: center column A, left column B, right column C, upper yoke D, lower yoke E, silicon steel sheet unit 10, first silicon steel sheet group 11, second silicon steel sheet group 12, positioning hole 13. Implementation

[0034] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0035] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0036] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments. Example

[0037] like Figure 1-6As shown, this embodiment of the invention provides a high-order longitudinally stepped iron core lamination structure with a low 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 right column C are located on the left and right sides of the central column A, while the upper yoke D and lower yoke E are located on the upper and lower sides of the central column A. The central column A, left column B, right column C, upper yoke D, and lower yoke E are all in contact with each other. Each of the central column A, left column B, right column C, upper yoke D, and lower yoke E includes several sequentially stacked silicon steel sheet units 10. Each silicon steel sheet unit 10 includes a first silicon steel sheet group 11 and a second silicon steel sheet group 12. The first silicon steel sheet group 11 and the second silicon steel sheet group 12 include multiple silicon steel sheets stacked longitudinally in opposite directions. The second silicon steel sheet group 12 is located above the first silicon steel sheet group 11. Equal-sized spaces are formed between the central column A and the left column B, and between the central column A and the right column C, for placing the coil.

[0038] The central column A is vertically positioned, with symmetrical pointed corners at both ends. These pointed corners are used to connect with the upper yoke D and the lower yoke E. The silicon steel sheet unit 10 corresponding to the central column A includes a first silicon steel sheet group 11 and a second silicon steel sheet group 12. During lamination, the first silicon steel sheet group 11 and the second silicon steel sheet group 12 corresponding to the central column A are stacked sequentially, and the stacking order of the first silicon steel sheet group 11 and the second silicon steel sheet group 12 is reversed, so that the uppermost silicon steel sheet of the corresponding first silicon steel sheet group 11 overlaps with the uppermost silicon steel sheet of the corresponding second silicon steel sheet group 12 but does not contact each other. Each silicon steel sheet in the silicon steel sheet unit 10 corresponding to the central column A is of the same size.

[0039] like Figure 1As shown in Figure 3-4, both the upper yoke D and the lower yoke E are horizontally arranged. The upper yoke D is positioned at the upper end of the central column A, and the lower yoke E is positioned at the lower end of the central column A. The upper yoke D and the lower yoke E are stacked longitudinally in opposite directions. The first silicon steel sheet group 11 and the second silicon steel sheet group 12 corresponding to the upper yoke D and the lower yoke E are stacked sequentially, and the stacking order of the silicon steel sheets in the first silicon steel sheet group 11 and the second silicon steel sheet group 12 corresponding to the upper yoke D is the opposite of the stacking order of the first silicon steel sheet group 11 and the second silicon steel sheet group 12 corresponding to the lower yoke E. The stacking order of the silicon steel sheets in the first silicon steel sheet group 11 and the second silicon steel sheet group 12 corresponding to the upper yoke D or the lower yoke E is also opposite, and the bottom silicon steel sheet of the first silicon steel sheet group 11 overlaps with the top silicon steel sheet of the second silicon steel sheet group 12. Taking the above yoke sheet 8 step as an example, the silicon steel sheets in the first silicon steel sheet group are stacked in order from right to left as 1234, and the silicon steel sheets in the second silicon steel sheet group are stacked in order from left to right as 5678. When stacking, the silicon steel sheets are stacked from bottom to top. At this time, silicon steel sheet 1 is located at the bottom layer and silicon steel sheet 8 is located at the top layer. Silicon steel sheet 8 and silicon steel sheet 4 overlap but do not contact each other, thus forming a sequentially arranged structure, and hiding an out-angle, that is, the number of out-angles formed by the silicon steel sheet unit is less than the number of silicon steel sheets.

[0040] The upper yoke D has a triangular notch 1 in its center, and the lower yoke E has a triangular notch 2 in its center. Triangular notches 1 and 2 are respectively spliced ​​with the sharp corner. To ensure better splicing of triangular notches 1 and 2 with the sharp corner, the triangular notch 1 corresponding to the first silicon steel sheet group 11 in the upper yoke D gradually decreases in size according to the stacking order, while the triangular notch 1 corresponding to the second silicon steel sheet group 12 in the upper yoke D gradually increases in size according to the stacking order. Similarly, the triangular notch 2 corresponding to the first silicon steel sheet group 11 in the lower yoke E gradually increases in size according to the stacking order, while the triangular notch 2 corresponding to the second silicon steel sheet group 12 in the lower yoke E gradually decreases in size according to the stacking order. The dimensions of the triangular notches 1 and 2 that contact the sharp corner, the first silicon steel sheet group 11, and the second silicon steel sheet group 12 are the same. Taking the upper yoke 8-step progression as an example, in the fourth and eighth layers, the dimensions of triangular notch 1 in the upper yoke, triangular notch 2 in the lower yoke, and the sharp corner of the central column are equal.

[0041] like Figure 1As shown in Figure 5-6, both the left column B and the right column C are vertically arranged. The left column B is located to the left of the middle column A, and the right column C is located to the right of the middle column A. The left column B is spliced ​​with the upper yoke D and the lower yoke E, and the right column C is spliced ​​with the upper yoke D and the lower yoke E. The stacking order of the left column B and the right column C is reversed, and the stacking order of the first silicon steel sheet group 11 and the second silicon steel sheet group 12 in the left column B and the right column C is also reversed, ultimately forming a sequentially arranged structure. Taking the left column 8 as an example, the silicon steel sheets in the first silicon steel sheet group are stacked in order from bottom to top as 1234, and the silicon steel sheets in the second silicon steel sheet group are stacked in order from top to bottom as 5678. At this time, silicon steel sheet 1 is located at the bottom layer and silicon steel sheet 8 is located at the top layer. Silicon steel sheet 8 and silicon steel sheet 4 overlap but do not touch each other, with three silicon steel sheets 765 in between. This forms a sequentially arranged structure and hides an out-of-angle, that is, the number of out-of-angles formed by the silicon steel sheet unit is less than the number of silicon steel sheets.

[0042] During the lamination process of the middle column A, left column B, right column C, upper yoke D, and lower yoke E, in order to improve the quality of the iron core lamination, the lamination spacing between the first silicon steel sheet group 11 and the second silicon steel sheet group 12 is equal. Furthermore, each silicon steel sheet is provided with a positioning hole 13, and multiple positioning holes 13 in each silicon steel sheet unit overlap each other.

[0043] During lamination, the upper yoke D and the lower yoke E are stacked horizontally. Specifically, the bottom silicon steel sheet of the first silicon steel sheet group 11 in the upper yoke D and the bottom silicon steel sheet of the first silicon steel sheet group 11 in the lower yoke E are staggered by a certain distance in the horizontal direction. At the same time, combined with the corresponding lamination order of the upper yoke D and the lower yoke E, the exit angle positions formed by the first silicon steel sheet group 11 and the second silicon steel sheet group 12 in the left column B, right column C, upper yoke D and lower yoke E are opposite. The size of the exit angle formed by the first silicon steel sheet group 11 and the second silicon steel sheet group 12 in the left column B, right column C, upper yoke D and lower yoke E gradually decreases to zero along the stacking order. Example

[0044] This embodiment also provides a method for stacking high-order longitudinal stepping cores with low exit angles, including the following steps:

[0045] Each silicon steel sheet unit corresponding to the central column is divided into a first group and a second group on an average basis.

[0046] Stack the first and second groups vertically in a symmetrical manner;

[0047] Each silicon steel sheet unit corresponding to the left column, right column, upper yoke and lower yoke is divided into the first group and the second group on an average basis.

[0048] The first and second groups are stacked vertically from bottom to top, so that the top silicon steel sheet of the first silicon steel sheet group and the bottom silicon steel sheet of the second silicon steel sheet group overlap each other, forming an outward angle with opposite directions between the first and second silicon steel sheet groups.

[0049] Using N pieces as a cycle, perform pre-stacking of the middle pillar, left pillar, right pillar, upper yoke piece, and lower yoke piece;

[0050] 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;

[0051] 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.

[0052] 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.

[0053] like Figure 1-6 As shown, the left column lamination steps are explained using an 8-step method as an example:

[0054] During lamination, the eight silicon steel sheets are first divided into two groups of four. The first group is stacked longitudinally with a spacing of 1 from bottom to top, and the resulting silicon steel sheets are arranged in the order of 1234. The second group is stacked longitudinally with a spacing of 1 from top to bottom, and the resulting silicon steel sheets are arranged in the order of 5678. The final silicon steel sheet order is 1234(8)765. At this time, the fourth and eighth silicon steel sheets overlap but do not touch, with a gap of 765 between them. Since the fourth and eighth silicon steel sheets overlap, seven exit corners are formed. Reducing one exit corner with the same number of steps can improve the magnetic flux flow performance and the no-load performance of the core. On the other hand, reducing the number of exit corners reduces the obstruction to the magnetic flux flow caused by the increase in the corner space due to the increase in the number of steps, thus improving the working efficiency of the core.

[0055] 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 high-order longitudinal stepping core lamination structure with a low outgoing angle, characterized in that: The system includes a central column, a left side column, a right side column, an upper yoke, and a lower yoke. The left and right side 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 side column, and right side column are all in contact with and connected to the upper and lower yokes. Each of the central column, left side column, right side column, upper yoke, and lower yoke comprises several sequentially stacked silicon steel sheet units. Each silicon steel sheet unit includes a first silicon steel sheet group and a second silicon steel sheet group. Multiple silicon steel sheets in the first silicon steel sheet group and multiple silicon steel sheets in the second silicon steel sheet group are stacked longitudinally in opposite directions. The second silicon steel sheet group is positioned above the first silicon steel sheet group. The uppermost silicon steel sheets of the first silicon steel sheet group and the uppermost silicon steel sheets of the second silicon steel sheet group are mutually... The two ends of the central column are provided with symmetrical sharp corners. The upper yoke has a triangular notch 1 in the middle and the lower yoke has a triangular notch 2 in the middle. The triangular notch 1 and the triangular notch 2 are respectively connected to the sharp corners. The triangular notch 1 corresponding to the first silicon steel sheet group in the upper yoke gradually decreases in the stacking order. The triangular notch 1 corresponding to the second silicon steel sheet group in the upper yoke gradually increases in the stacking order. The triangular notch 2 corresponding to the first silicon steel sheet group in the lower yoke gradually increases in the stacking order. The triangular notch 2 corresponding to the second silicon steel sheet group in the lower yoke gradually decreases in the stacking order. The sharp corners and the triangular notches 1 and 2 that are in contact with each other are the same size.

2. The high-order longitudinal stepping core lamination structure with low outgoing angle according to claim 1, characterized in that: The stacking interval between the first silicon steel sheet group and the second silicon steel sheet group is equal.

3. The high-order longitudinal stepping core lamination structure with low outgoing angle according to claim 2, characterized in that: The first silicon steel sheet group and the second silicon steel sheet group corresponding to the middle column, left column, right column, upper yoke and lower yoke are stacked in sequence.

4. The high-order longitudinal stepping core lamination structure with low outgoing angle according to claim 1, characterized in that: Each of the silicon steel sheets is provided with positioning holes, and the multiple positioning holes in each silicon steel sheet unit overlap with each other.

5. A high-order longitudinal stepping core lamination structure with a low out-of-angle as described in claim 1, characterized in that, The exit angles formed by the first and second silicon steel sheet groups within the left and right columns, upper and lower yokes are in opposite positions, and the size of the exit angles formed by the first and second silicon steel sheet groups within the left and right columns, upper and lower yokes gradually decreases to zero along the stacking sequence.

6. A high-order longitudinal stepping core lamination structure with a low out-of-angle according to claim 2, characterized in that: The number of out-of-angle segments formed by the silicon steel sheet unit is less than the number of silicon steel sheets.

7. A method for forming a high-order longitudinally stepping core lamination structure with a low outgoing angle as described in claim 1, characterized in that, Includes the following steps: Each silicon steel sheet unit corresponding to the middle column, left column, right column, upper yoke and lower yoke is equally divided into the first silicon steel sheet group and the second silicon steel sheet group. Multiple silicon steel sheets in the first silicon steel sheet group and multiple silicon steel sheets in the second silicon steel sheet group are stacked longitudinally in opposite directions to form a sequential arrangement structure, such that the uppermost silicon steel sheet in the first silicon steel sheet group and the lowermost silicon steel sheet in the second silicon steel sheet group overlap but do not touch each other. 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.

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