Method for assembling a split core

Abstract

The application belongs to the technical field of converter transformers, and relates to a method for assembling a disassembled iron core, and a tool for assembling the disassembled iron core. The tool for assembling the disassembled iron core comprises a tool body, which is a rectangular frame structure. A plurality of pairs of guide rings are symmetrically and fixedly arranged in pairs from left to right along the length direction of the tool body, and the positions of the guide rings correspond to the positions of positioning columns. The assembling tool is laid on a cushion beam, and the levelness of the assembling tool is measured by using a laser level. After a first iron core frame is positioned, the perpendicularity of an iron core column and the levelness of a clamping piece are measured and adjusted. The height difference of the semicircular iron core columns of two adjacent iron core frames is not more than 2 mm. The size deviation of the gap between the two adjacent iron core frames is less than or equal to 4 mm. After the semicircular iron core columns of the two iron core frames are spliced into an iron core column main column, two polyester bands are bound in the interval outside the iron core column without weft bands. After being lifted by a special lifting device, the iron core frame is dropped into the bottom of an oil tank. The application realizes the rapid and accurate on-site assembly of the iron core frame.

Description

Technical Field

[0001] This invention belongs to the field of converter transformer technology, specifically relating to a method for assembling a disassembled iron core. Background Technology

[0002] The core of a converter transformer (especially a large converter transformer) is characterized by its large size, heavy weight, and difficulty in transportation. In order to solve the problem of installing converter transformers in remote areas where transportation is not possible, the core of a converter transformer usually needs to adopt a disassembled design structure, which breaks down the core into several separate core frames. Each core frame is a separate unit, and the core frames can be independently stacked, assembled, bound, and transported.

[0003] Converter transformers typically employ a single-phase four-column core structure for disassembly and transportation. Considering the need for disassembly and transportation, the core is disassembled into three U-shaped structures. An 8mm longitudinal oil channel is installed between the core columns, with phenolic paperboard pads used for the channel spacers. The core is then disassembled into three core frame transport units at the longitudinal oil channels. Because the longitudinal oil channel size between the core frames is only 8mm, without specialized assembly tools and methods, it is difficult to ensure that the position of the core frames and the longitudinal oil channel dimensions meet process requirements during assembly. If the longitudinal oil channel dimensions exceed the tolerance, the core column diameter will be out of tolerance, preventing the coils from being properly assembled. Furthermore, the positioning structure of the converter transformer core frame differs significantly from that of an AC transformer. Therefore, a dedicated positioning and assembly method and specialized tooling need to be designed based on the characteristics of the converter transformer core frame's positioning structure to ensure that the core position meets process requirements during assembly. Currently, there is no dedicated assembly method for disassembly-type cores in converter transformers. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides a method for assembling a disassembled iron core. The technical solution adopted by this invention is as follows:

[0005] A method for assembling a disassembled iron core, wherein the disassembled iron core comprises three iron core frames, and four positioning posts are fixedly installed on the lower surface of the lower clamping parts of each iron core frame, comprising the following steps:

[0006] Step 1: Design the assembly fixture for the disassembled iron core, including the fixture body, which is a rectangular frame structure. Along the length of the fixture body, guide rings 1, 2, 3, 4, 5, and 6 are symmetrically fixed in pairs from left to right. The positions of guide rings 1, 2, 3, 4, 5, and 6 correspond to the positioning posts, and the center distance between two adjacent pairs of guide rings deviates from the position required by the drawing design by ≤1mm. Guide rings 3, 4, 5, and 6 are elliptical structures.

[0007] Step 2: Lay the assembly fixture on the support beam and use a laser level to measure the levelness of the assembly fixture. The deviation should be less than 1mm.

[0008] Step 3: After the first core frame is in place, measure the verticality of the core column and the horizontality of the clamp, and make adjustments. If the deviation is out of tolerance, adjust by increasing or decreasing the number of shims in the guide ring.

[0009] Step 4: Measure the height difference of the semicircular core columns of two adjacent core frames. The difference should not exceed 2mm; the gap between two adjacent core frames should have a deviation of ≤4mm.

[0010] Step 5: After the semi-circular iron core columns of the two iron core frames are assembled into a main iron core column, two polyester strips are tied between the outer non-woven strips of the iron core column, each strip consisting of two layers.

[0011] Step 6: Assemble the iron core column that meets the process requirements and is firmly bound, and then lower it into the bottom of the oil tank using a special hoisting equipment.

[0012] Preferably, the tooling body includes two fixed channel steels in the length direction and six positioning plates in the width direction. The two fixed channel steels and the six positioning plates are fixedly combined into a rectangular frame structure by bolt connection.

[0013] Preferably, hanging plates are fixedly installed on the upper surfaces of both ends of the positioning plate, and several lifting lugs are fixedly installed on the upper surface of the fixed channel steel.

[0014] The beneficial effects of this invention are:

[0015] This invention utilizes the feature of the positioning posts fixedly installed in the lower clamp of the iron core frame to design a tooling body with a rectangular frame structure. Furthermore, a guide ring corresponding to the position of the positioning post is fixedly installed on the tooling body. When assembling the iron core frame, the positioning post falls into the guide ring, thus realizing the rapid and accurate on-site assembly of the iron core frame. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of an existing converter transformer core;

[0017] Figure 2 This is a schematic diagram of the disassembled structure of an existing converter transformer core;

[0018] Figure 3 This is a top view of the assembly tooling according to an embodiment of the present invention;

[0019] Figure 4 This is a left-facing front view of the assembly fixture according to an embodiment of the present invention;

[0020] In the diagram, 1 is the fixed channel steel, 2 is the positioning plate, 3 is the guide ring one, 4 is the guide ring two, 5 is the lifting plate, 6 is the lifting lug, 7 is the iron core column, 8 is the iron core frame, 9 is the guide ring three, 10 is the guide ring four, 11 is the guide ring five, and 12 is the guide ring six. Detailed Implementation

[0021] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0022] like Figure 1 The diagram shown is a structural schematic of an existing converter transformer core. Converter transformer cores typically employ a single-phase four-column structure. Figure 1 The converter transformer core consists of four core columns 7.

[0023] like Figure 2 The diagram shows a disassembled structure of an existing converter transformer core. Considering transportation needs, the converter transformer core is generally a disassembled core. During transportation, the core is disassembled into three U-shaped core columns. The two middle core columns 7 are divided into two halves from the center, with an 8mm longitudinal oil channel between adjacent halves. The three U-shaped core columns are then fixedly assembled into core frames 8, and these three core frames 8 serve as three separate transportation units for long-distance transport. Four positioning posts are fixedly installed on the lower surface of the lower clamping parts of each core frame 8.

[0024] After the core frame 8 is transported to the site, the three core frames 8 need to be assembled into a complete single-phase four-column converter transformer core. To ensure that the longitudinal oil passage dimensions between adjacent core halves and the core column diameter meet the process requirements when the three core frames 8 are assembled into a whole, this invention designs a disassembled core assembly method, including the following steps:

[0025] Step 1: Design the assembly fixture for the disassembled iron core, including the fixture body. For example... Figure 3 The image shown is a top-view view of the assembly fixture according to an embodiment of the present invention; as shown... Figure 4The image shown is a left-facing front view of the assembly fixture according to an embodiment of the present invention. The fixture body is a rectangular frame structure, consisting of two fixed channel steels 1 and six positioning plates 2. Guide rings 1-3, 2-4, 3-9, 4-10, 5-11, and 6-12 are symmetrically fixed in pairs at both ends of the upper surface of the six positioning plates 2 by welding. The guide rings should not be too close to the ends of the positioning plates 2, and space needs to be reserved at the ends of the positioning plates 2 for installing the fixed channel steels 1. The positions of guide rings 1-3, 2-4, 3-9, 4-10, 5-11, and 6-12 correspond to the positioning posts. Six positioning plates 2 are spaced apart and arranged in parallel. The six positioning plates 2 are arranged from left to right in the following order: guide ring 1 (3), guide ring 2 (4), guide ring 3 (9), guide ring 4 (10), guide ring 5 (11), and guide ring 6 (12). Two parallel fixed channel steels 1 are fixedly installed on the upper surface of both ends of the positioning plates 2 by bolt connection. The fixed channel steels 1 are located outside the guide rings. The fixed channel steels 1 and positioning plates 2 are designed with a bolt connection structure. This is because the tooling is heavy and inconvenient to transport as a whole, and the bolt connection structure allows for flexible adjustment of the position of the positioning plates 2 to meet the requirements of different sized iron core frames 8.

[0026] Furthermore, guide rings 3-9, 4-10, 5-11, and 6-12 are elliptical in shape. After the first core frame 8 (the left core frame 8) is assembled, the elliptical guide rings can facilitate the adjustment of the position of the second (the middle core frame 8) and the third core frame 8 (the right core frame 8) during assembly, so as to meet the process requirements of the 8mm longitudinal oil passage.

[0027] The guide rings 1-3, 2-4, 3-9, 4-10, 5-11, and 6-12 should preferably be made of Q235-B steel plate. The Q235-B steel plate material can ensure that the positioning post falls smoothly into the guide ring according to the drawing position.

[0028] Lifting plates 5 are fixedly installed at both ends of the upper surface of the positioning plate 2 by welding, and a pair of lifting lugs 6 are fixedly installed on the upper surface of the fixing channel steel 1 by welding. The lifting plates 5 and lifting lugs 6 are used for the assembly method of lifting and transporting disassembled iron cores.

[0029] The lifting plate 5 and lifting lug 6 should preferably be made of Q235-B steel plate. Q235-B steel plate can ensure the mechanical strength of the lifting plate 5 and lifting lug 6 and meet the lifting and handling requirements of the assembly tooling.

[0030] The material of positioning plate 2 should preferably be Q235-B steel plate.

[0031] This assembly fixture effectively simulates the design structure and dimensions of the lower positioning column of the converter transformer core frame 8, ensuring the positioning dimensions of the core frame 8 after assembly and guaranteeing that the transformer body can smoothly fall into the positioning component at the bottom of the tank when it is in place.

[0032] Step 2: Lay the assembly fixture on the support beam and use a laser level to measure the levelness of the assembly fixture. The deviation should be less than 1mm.

[0033] Step 3: After the first core frame 8 is in place, measure the verticality of the core column 7 and the horizontality of the clamp, and make adjustments. If the deviation is out of tolerance, adjust by increasing or decreasing the number of shims in the guide ring.

[0034] Step 4: Measure the height difference of the semicircular iron core column between two adjacent iron core frames 8. The difference should not exceed 2mm; the gap between two adjacent iron core frames 8 should have a size deviation of ≤4mm.

[0035] Step 5: Bind two layers of polyester tape within the intervals of the non-woven tape on the outside of the iron core column 7, each layer consisting of two layers, to increase the overall mechanical strength of the iron core column 7. The non-woven tape is a material used to bind the iron core column 7; after curing, it increases the mechanical strength of the iron core column 7. This step is part of the assembly process of the iron core frame 8. The semi-circular iron core columns of the two iron core frames 8 can only be bound together with polyester tape after they are assembled into a main column.

[0036] Step 6: Assemble the iron core column 7, which meets the process requirements and is firmly bound, and then lower it into the bottom of the oil tank using a special hoisting equipment.

[0037] In the embodiments of the present invention, all technical features not described in detail are existing technologies or conventional technical means, and will not be repeated here.

[0038] Finally, it should be noted that the above embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit them. The scope of protection of the present invention is not limited thereto. Those skilled in the art should understand that any person skilled in the art can modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the technical scope disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the scope of protection of the present invention.

Claims

1. A method for assembling a disassembled iron core, wherein the disassembled iron core comprises three iron core frames, and four positioning posts are fixedly provided on the lower surface of the lower clamping parts of each iron core frame, characterized in that... Includes the following steps: Step 1: Design the assembly fixture for the disassembled iron core, including the fixture body, which is a rectangular frame structure. Along the length of the fixture body, guide rings 1, 2, 3, 4, 5, and 6 are symmetrically fixed in pairs from left to right. The positions of guide rings 1, 2, 3, 4, 5, and 6 correspond to the positioning posts, and the center distance between two adjacent pairs of guide rings deviates from the position required by the drawing design by ≤1mm. Guide rings 3, 4, 5, and 6 are elliptical structures. Step 2: Lay the assembly fixture on the support beam and use a laser level to measure the levelness of the assembly fixture. The deviation should be less than 1mm. Step 3: After the first core frame is in place, measure the verticality of the core column and the horizontality of the clamp, and make adjustments. If the deviation is out of tolerance, adjust by increasing or decreasing the number of shims in the guide ring. Step 4: Measure the height difference of the semicircular core columns of two adjacent core frames. The difference should not exceed 2mm; the gap between two adjacent core frames should have a deviation of ≤4mm. Step 5: After the semi-circular iron core columns of the two iron core frames are assembled into a main iron core column, two polyester strips are tied between the outer non-woven strips of the iron core column, each strip consisting of two layers. Step 6: Assemble the iron core column that meets the process requirements and is firmly bound, and then lower it into the bottom of the oil tank using a special hoisting equipment.

2. The method for assembling a disassembled iron core according to claim 1, characterized in that, The tooling body includes two fixed channel steels in the length direction and six positioning plates in the width direction. The two fixed channel steels and six positioning plates are fixedly combined into a rectangular frame structure by bolt connection.

3. The method for assembling a disassembled iron core according to claim 2, characterized in that, Hanging plates are fixedly installed on the upper surfaces of both ends of the positioning plate, and several lifting lugs are fixedly installed on the upper surface of the fixed channel steel.

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