A core structure design method and system based on accessory optimization

Abstract

The present invention proposes a core structure design method based on accessory optimization, which is as follows: Read the core design scheme, complete the optimization of the core accessories, and indicate the design surface pressure, core capacity, design magnetic density, and iron loss performance of the core in the core design scheme; The silicon steel sheets constituting the core and their dimensions are also indicated in the core design scheme. According to the silicon steel sheet dimensions and stress curves, the aperture diameters of the process holes or through holes are respectively determined, and the positions of the process holes or through holes are respectively determined according to the design surface pressure; Select a stepping form according to the core capacity to ensure the iron loss performance. The stepping form includes the joint form, the number of joints, and the stepping amount; Select the yoke structure of the core according to the design magnetic density of the core, and complete the selection of the clamping structure and fasteners of the core to complete the overall design of the core structure. The present invention provides an optimal accessory manufacturing optimization scheme by the magnetic performance conditions required for the actual core structure design, and improves the production efficiency of accessories.

Description

Technical Field

[0001] The present invention relates to the technical field of computer-aided design, and particularly relates to a core structure design method and system based on accessory optimization. Background Art

[0002] At present, the structural design of transformer cores completely serves their magnetic properties, ignoring the influence of external parts on the magnetic properties of the cores. This results in a serious mismatch between the theoretical magnetic properties of the core structure design and the magnetic properties in actual production tests. In addition, due to the neglect of accessories, the pass rate of accessory quality is too low, leading to a low qualified rate, affecting production efficiency, and even potentially causing safety problems.

[0003] In the existing core structure design, there is no accessory precision design. Only two-dimensional CAD drawings are provided to confirm the basic design dimensions of the accessories, and there are no requirements for their manufacturing precision, materials, and processes, or the requirements are too high to enable production. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the defects existing in the prior art. The present invention proposes a core structure design method and system based on accessory optimization, which provides an optimal accessory optimization scheme according to the relevant core structure, including parameters such as the manufacturing precision, manufacturing materials, and processes of the accessories, so as to provide a more reasonable core structure design scheme; collect the foregoing parameters, rely on this set of systems to perform magnetic property simulation based on the core structure, confirm the stability of the results, and then production can be launched.

[0005] To solve the above technical problems, the technical solution adopted by the present invention is: a core structure design method based on accessory optimization, specifically as follows:

[0006] Read the core design scheme, complete the optimization of the core accessories, and indicate the design surface pressure, core capacity, design magnetic density of the core, and iron loss performance in the core design scheme;

[0007] The core design scheme also indicates the silicon steel sheets constituting the core and their dimensions. First, confirm the aperture of the process hole or the through hole according to the silicon steel sheet dimensions and the stress curve, and then confirm the position of the process hole or the through hole according to the design surface pressure;

[0008] Select a step form according to the core capacity to ensure the iron loss performance, and the step form includes the joint form, the number of joints, and the step amount;

[0009] Select the yoke structure of the core according to the design magnetic density of the core, and complete the selection of the clamp structure and fasteners of the core to complete the overall design of the core structure.

[0010] Further, the aperture of the process hole or the through hole is confirmed according to the following steps: obtain the minimum sheet width of the silicon steel sheets constituting the iron core, and based on its stress curve, obtain the aperture α of the process hole or the through hole such that α ≤ β - 2γ;

[0011] Where α is the aperture of the process hole or the through hole, β is the minimum sheet width of the silicon steel sheets of the iron core, and γ is the influence diameter corresponding to the aperture α.

[0012] Further, the number of fixing screws required is confirmed according to the designed surface pressure of the iron core, and the aperture of the process hole or the through hole is not greater than the screw diameter, i.e., α ≤ θ;

[0013] Where α is the aperture of the process hole or the through hole, and θ is the screw diameter.

[0014] Further, the aperture α of the process hole or the through hole satisfies α ≤ β - 2γ and α ≤ θ.

[0015] Further, the total number of the process holes and the through holes is not less than 2, and the difference in the number between the process holes and the through holes is not greater than 1; the process holes and the through holes are arranged at intervals on the silicon steel sheets, and the distance between the process holes and the through holes is the same.

[0016] Further, the iron loss performance is calculated according to the following formula:

[0017] ,

[0018] In the formula, k is the joint form parameter, k1 is the material parameter of the silicon steel sheets selected for making the iron core, a is the number of joints, and b is the step size;

[0019] The number of joints is calculated according to the following formula:

[0020] ,

[0021] In the formula, m is the iron core capacity correction factor, and c is the iron core capacity;

[0022] The step size is calculated according to the following formula:

[0023] b = a - 2,

[0024] In the formula, a is the number of joints.

[0025] Further, the cross-sectional shape of the yoke structure includes circular, oblong, and oval. The cross-sectional shape of the yoke structure is selected according to the cross-sectional filling rate. The cross-sectional filling rate of the circular cross-section is not less than 85%, the cross-sectional filling rate of the oblong cross-section is 75% - 85%, and the cross-sectional filling rate of the oval cross-section is 70% - 75%;

[0026] During the selection process of the yoke structure, the selection is completed based on performance and price factors. The following formula is used to judge the cost performance parameter A of the selected yoke structure:

[0027] A = p0 / xρ b ;

[0028] Wherein, p0 is the unit iron loss of silicon steel sheets, with the unit of w / kg, determined by material parameters; x is the price, determined by the current pricing; ρ b is the cross-sectional filling rate.

[0029] Furthermore, the clamping structure includes steel plate clamps, bent clamps, temporary clamps, and channel steel clamps. The type of the clamping structure is selected according to the following method:

[0030] If a specified type of clamping structure is selected, mechanical simulation is required. If the type of the clamping structure is not specified, the selection is completed after comprehensive judgment based on strength, precision, and cost factors in sequence.

[0031] Furthermore, the fasteners include metal fasteners and non-metal fasteners. The metal fasteners and non-metal fasteners are selected according to the tension strength and the sizes of process holes and through holes.

[0032] Furthermore, a core structure design system based on accessory optimization includes a process hole and through hole design module, an iron loss performance design module, a yoke structure design module, and a clamping structure and fastener design module. The accessory optimization design of the core structure is completed through the process hole and through hole design module, the iron loss performance design module, the yoke structure design module, and the clamping structure and fastener design module according to the core structure design method based on accessory optimization.

[0033] Compared with the prior art, the beneficial effects of the present invention include:

[0034] 1) By providing a set of accessory optimization schemes based on the original core structure design, it is possible to design the required magnetic performance conditions through the actual core structure and provide the optimal accessory manufacturing optimization scheme;

[0035] The production efficiency of accessories is accelerated. The optimization scheme greatly reduces manual operations and can also improve the production precision, making the production process of each part more closely linked. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The disclosure of the present invention is described with reference to the accompanying drawings. It should be understood that the drawings are only for illustrative purposes and are not intended to limit the protection scope of the present invention. In the drawings, the same reference numerals are used to refer to the same components. Among them:

[0037] Figure 1Schematically shows a core structure design method optimized based on accessories;

[0038] Figure 2 Schematically shows a stress curve;

[0039] Figure 3 Schematically shows the relationship between the aperture size and the stress influence range;

[0040] Figure 4 Schematically shows the structure of a core structure design system optimized based on accessories. Specific embodiments

[0041] It is easy to understand that according to the technical solution of the present invention, without changing the essential spirit of the present invention, those of ordinary skill in the art can propose various structural ways and implementation ways that can be mutually replaced. Therefore, the following specific embodiments and the accompanying drawings are only exemplary illustrations of the technical solution of the present invention, and should not be regarded as all of the present invention or as a limitation or restriction on the technical solution of the present invention.

[0042] According to an embodiment of the present invention, it is combined with Figure 1 Shown. A core structure design method optimized based on accessories is as follows:

[0043] Read the original core design scheme, and indicate the design surface pressure, core capacity, design magnetic density, and iron loss performance of the core in the foregoing original core design scheme;

[0044] The silicon steel sheets constituting the core and their dimensions are also indicated in the foregoing original core design scheme. First, confirm the aperture of the process hole or the through hole according to the dimensions of the foregoing silicon steel sheets and the stress curve, and then confirm the position of the process hole or the through hole according to the design surface pressure;

[0045] Select a step form according to the core capacity to ensure the iron loss performance. The foregoing step form includes a joint form, the number of joints, and the step amount;

[0046] Select the yoke structure of the core according to the design magnetic density of the core, and complete the selection of the clamping structure and fasteners of the core to complete the overall design of the core structure.

[0047] Such as Figure 4As shown, a core structure design system based on accessory optimization includes a process hole and through-hole design module, a step form design module, a yoke structure design module, and a clamp structure and fastener design module. Based on a core structure design method based on accessory optimization, the aperture and position of the process hole and through-hole are determined in the process hole and through-hole design module, the joint form, the number of joints, and the step amount are determined in the step form design module, the yoke structure is selected in the yoke structure design module, and the clamp structure and fasteners are selected in the clamp structure and fastener design module.

[0048] The following specifically describes the determination process of the aperture, number, and position of the process hole or through-hole. Since the aperture confirmation methods of the process hole and through-hole are exactly the same, the only difference between the process hole and through-hole is the different requirements for mechanical properties. In the core design scheme, the hole shapes of both the process hole and through-hole are round holes.

[0049] Taking the process hole as an example, first, collect the design parameters of the process hole. According to the silicon steel sheets and their dimensions that make up the core indicated in the read core design scheme, determine the aperture of the process hole based on the dimensions of the silicon steel sheets obtained above and the stress curve corresponding to the round hole. The stress curve is the influence curve of the distance from the edge of the silicon steel sheet to the position of the round hole with different apertures on the unit iron loss of the silicon steel sheet.

[0050] For the selection of the aperture of the process hole, first record the minimum value of the sheet width of the silicon steel sheet mentioned above, denoted as β, and the aperture is denoted as α. Select a suitable aperture α based on the stress curve mentioned above and read the corresponding influence diameter of this aperture. The stress curve is as Figure 2 shown. Denote the influence diameter as γ, so that α ≤ β - 2γ. The relationship between the aperture size and the stress influence range is as Figure 3 shown.

[0051] After determining the apertures of the process hole and through-hole according to the above process, determine the positions of the process hole and through-hole. The positions of the process hole and through-hole are mainly determined by the screw strength and the number of screws. Determine the screw strength and the number of screws according to the designed surface pressure. That is, when the strength of a single screw can meet the designed surface pressure, the process hole and through-hole are located at the center position of the silicon steel sheet. If the strength of a single screw cannot meet the requirement of the designed surface pressure, then increase the number of screws to meet the requirement of the designed surface pressure. After confirming the screw strength, the upper limit of the screw diameter, that is, the process hole diameter, can be determined, denoted as θ. When α ≤ β - 2γ and at the same time α ≤ θ, the aperture size can be completely determined.

[0052] Regarding the distribution of the through holes and process holes on the silicon steel sheet, the total number of through holes and process holes is not less than 2, where the number of through holes is at least 2, and the process holes and through holes are arranged at intervals. The following is an example. When the total number of through holes and process holes is 2, they are both through holes. When the total number of through holes and process holes is 3, the number of through holes is 2, the number of process holes is 1, the process hole is set between the two through holes and the distance between the process hole and the through holes is the same. If the total number of process holes and through holes continues to increase, the number of process holes and through holes is basically the same, and the process holes and through holes are arranged at intervals on the silicon steel sheet, and the distance between the process holes and the through holes is the same.

[0053] It should be noted that the process holes are opened for rapid stacking of the iron core. Its significance lies in accelerating the stacking efficiency of the iron core and not providing surface pressure, while the opening of the process holes will cause the magnetic properties of the iron core to decline. The through holes are set to provide the main surface pressure. To avoid repeated punching, the aforementioned through holes can be used as process holes to avoid the decline of the magnetic properties of the iron core due to repeated opening of process holes. Therefore, there is a situation where the process holes and through holes are shared. The intuitive manifestation is that the apertures of the process holes and through holes are the same. Therefore, it is necessary to judge whether the apertures of the aforementioned through holes and process holes are the same.

[0054] Select the joint form, the number of joints and the step size according to the capacity of the iron core in the design scheme to ensure the iron loss performance of the manufactured iron core. Denote the number of joints as a, the step size as b, the joint form parameter as k, the iron core capacity as c, and the iron loss performance as λ. Then the number of joints ; the step size b = a - 2, and the iron loss performance , where k1 is the material parameter of the silicon steel sheet selected for making the iron core.

[0055] The aforementioned k is the joint form parameter, and the acquisition method is the ratio of the step size area to the joint overlap area. k1 is the iron loss material parameter of the silicon steel sheet selected for making the iron core and can be directly measured.

[0056] Confirm the number of joints and the step size of the iron core according to the previous formula. For example, when the iron core capacity is 800 KVA, directly obtain the number of joints and the step size according to the aforementioned formula. Specifically, the range of the number of joints is 5 - 7, and the range of the step size is 3 - 4 mm. Arbitrarily select according to the obtained range of the number of joints and the step size. For example, if the number of joints is set to 6, the step size is set to 3.5 mm, as long as it falls within the obtained range of the number of joints and the step size.

[0057] The following describes the selection method of the yoke structure. During this selection process, the designed magnetic density of the iron core determines the upper threshold of the cross-sectional filling rate of the iron core, and the magnetic density determines the no-load loss of the iron core. The aforementioned yoke structure includes a circular cross-section, an oblong cross-section, and an oval cross-section. The cross-sectional filling rate of the circular cross-section is not less than 85%, the cross-sectional filling rate of the oblong cross-section is 75%-85%, and the cross-sectional filling rate of the oval cross-section is 70%-75%.

[0058] During the selection process, the selection principles include performance and price. In terms of performance, they are arranged in the order of the cross-sectional filling rate of the iron core. In terms of price, the circular cross-section is greater than the oval cross-section, which is greater than the oblong cross-section. Therefore, during the specific selection of the yoke structure, the following formula is used to judge the cost performance parameter A of the selected yoke structure:

[0059] A = p0 / xρ b ;

[0060] In the above formula, p0 is the unit iron loss of the silicon steel sheet, with the unit of w / kg, which is determined by the material parameters; x is the price, which is determined by the pricing at that time; ρ b is the cross-sectional filling rate.

[0061] The following specifically describes the selection process of the clamping structure. The available clamping structures include steel plate clamps, bent clamps, temporary clamps, and channel steel clamps. The clamping structure is selected according to the following method:

[0062] 1) When selecting a specified type of clamping structure, that is, if the selected clamping structure is a steel plate clamp, a mechanical simulation is carried out to test whether it can meet the mechanical performance requirements of the entire iron core when this type of clamp is selected. If it meets the design requirements and safety requirements, it can be selected;

[0063] 2) When the type of the clamping structure is not specified, the type of the clamping structure is judged in turn according to strength, precision, and cost, so as to complete the selection. In this method, the types of the aforementioned clamping structures are arranged in the order of steel plate clamps, bent clamps, temporary clamps, and channel steel clamps. Among the clamping structures used in the present invention, the steel plate clamp is a multi-variety clamping connector connected to the steel structure, which is more flexible in installation, disassembly, or readjustment while ensuring a safe load, so it saves more costs. The bent clamp has the advantages of few parts, high machining precision, accurate positioning, simple assembly, and simple surface treatment and painting processes. Compared with traditional profiles (square tubes, channel steels), the bent part has flexible design parameters, and the precision can reach ±0.5 mm. After cutting, it is bent and formed by a numerical control bending machine to ensure the forming size. The channel steel clamp has strong bearing capacity and is easy to process and install. The temporary clamp is a channel steel clamp with a unified size used for temporarily clamping the iron core.

[0064] The following specifically describes the selection logic when the type of clamping structure is not specified. The steel plate clamping parts, bent clamping parts, temporary clamping parts, and channel steel clamping parts are respectively assigned values according to strength, precision, and cost factors. Then, according to the threshold ranges set for the strength, precision, and cost of the clamping structure in the iron core design scheme, the type of clamping structure is selected in the order of strength, precision, and cost.

[0065] During the specific selection process, if the strength requirement is high, such as a clamping part that needs to have more than three holes, the steel plate clamping part is selected; if cost factors are also considered, the channel steel clamping part is selected; if only one hole needs to be opened, the bent clamping part is selected because the bent clamping part has the strongest plasticity and the highest precision, and can meet most design requirements; if only temporary clamping is required, the temporary clamping part is selected.

[0066] If the steel plate clamping part is selected, the subsequent welding process plan is designed. First, welding materials suitable for the welding strength are selected, and then the welding shape, welding temperature, wire feeding speed, and welding method are selected according to the iron core design. The welding methods include fusion welding and pressure welding.

[0067] Furthermore, based on the premise of selecting the steel plate clamping part, the subsequent welding process plan is designed. First, the welding material is selected. Determine the type of welding material according to whether the steel plate clamping part is qualified. If the steel plate clamping part is unqualified when leaving the factory, alloy steel solder is selected, otherwise galvanized sheet solder can be selected. Then the welding shape is selected. The aforementioned welding shapes include butt joints, corner joints, T-shaped joints, and lap joints. The non-destructive welding process is selected. The welding temperature is fixed at 250 - 270 °C. During the welding process, the wire feeding speed is proportional to the welding current magnitude.

[0068] Furthermore, based on the premise of selecting the bent clamping part, materials are selected according to the bending process, bending angle, and bending complexity. The aforementioned bent clamping part is subjected to paint coating treatment after surface treatment, and at the same time, interference simulation is carried out on the bent clamping part to confirm that the bent clamping part meets the strength requirements. After the simulation is qualified, the bent clamping part plan is output.

[0069] Furthermore, based on the premise of selecting the channel steel clamping part, after successively confirming the position of the welding part and the selection of the channel steel, mechanical simulation is carried out synchronously. After the simulation is qualified, the channel steel clamping part plan is output.

[0070] Subsequently, it enters the fastener design stage. The fasteners include metal fasteners and non-metal fasteners;

[0071] If metal fasteners are selected, according to the process holes and through holes of the iron core, the sizes of the bolts and screws are confirmed, and steel straps are selected.

[0072] If non-metal fasteners are selected, the non-metal fasteners include plastic steel belts and non-metallic belts. Non-metal fasteners with a matching tension strength are selected according to the iron core design.

[0073] The technical effects of the iron core structure design method and system based on accessory optimization are further described below in conjunction with embodiments.

[0074] As shown in Table 1 below, which are the parameters of the iron core structure design scheme before modification,

[0075] Table 1

[0076]

[0077] After the iron core structure design method and system based on accessory optimization optimize and adjust the aforementioned iron core structure design scheme, its parameters are as shown in Table 2 below:

[0078] Table 2

[0079]

[0080] By providing an optimal accessory optimization scheme based on the relevant iron core structure, including parameters such as the manufacturing precision, manufacturing materials, and processes of the accessories, a more reasonable iron core structure design scheme can be provided; collecting the aforementioned parameters and relying on this set of systems for magnetic performance simulation based on the iron core structure to confirm the stability of the results, production can then be launched.

[0081] The technical scope of the present invention is not limited to the content described above. Those skilled in the art can make various deformations and modifications to the above embodiments without departing from the technical idea of the present invention, and these deformations and modifications should all fall within the protection scope of the present invention.

Claims

1. A core structure design method based on accessory optimization, characterized in that The details are as follows: Read the iron core design scheme, complete the optimization of the iron core accessories, and indicate the design surface pressure, iron core capacity, design magnetic density, and iron loss performance of the iron core in the iron core design scheme; The silicon steel sheets that make up the iron core and their dimensions are also indicated in the iron core design scheme. First, confirm the aperture of the process hole or the through hole according to the silicon steel sheet size and the stress curve, and then confirm the position of the process hole or the through hole according to the design surface pressure. The aperture of the process hole or the through hole is confirmed according to the following steps: obtain the minimum sheet width of the silicon steel sheets that make up the iron core, and based on its stress curve, obtain the aperture α of the process hole or the through hole, where α ≤ β - 2γ; Where α is the aperture of the process hole or the through hole, β is the minimum sheet width of the silicon steel sheets of the iron core, and γ is the influence diameter corresponding to the aperture α; Select the stepping form according to the iron core capacity to ensure the iron loss performance. The stepping form includes the joint form, the number of joints, and the stepping amount. The iron loss performance is calculated according to the following formula: ， In the formula, k is the joint form parameter, k1 is the material parameter of the silicon steel sheets selected for making the iron core, a is the number of joints, and b is the stepping amount; The number of joints is calculated according to the following formula: ， In the formula, m is the iron core capacity correction factor, and c is the iron core capacity; The stepping amount is calculated according to the following formula: b = a - 2, In the formula, a is the number of joints; Select the yoke structure of the iron core according to the design magnetic density of the iron core, and complete the selection of the clamping structure and fasteners of the iron core to complete the overall design of the iron core structure.

2. The core structure design method based on accessory optimization according to claim 1, wherein Confirm the number of fixing screws required according to the design surface pressure of the iron core. The aperture of the process hole or the through hole is not greater than the screw diameter, that is, α ≤ θ; Where α is the aperture of the process hole or the through hole, and θ is the screw diameter.

3. The method for designing a core structure optimized based on accessories according to claim 2, characterized in that, The total number of the process holes and the through holes is not less than 2, and the difference in the number of the process holes and the through holes is not greater than 1. The process holes and the through holes are arranged at intervals on the silicon steel sheets, and the distance between the process holes and the through holes is the same.

4. The method for designing a core structure optimized based on accessories according to claim 1, characterized in that The cross-sectional shape of the yoke structure includes circular, oblong, and oval. Select the cross-sectional shape of the yoke structure according to the cross-sectional filling rate. The cross-sectional filling rate of the circular cross-section is not less than 85%, the cross-sectional filling rate of the oblong cross-section is 75% - 85%, and the cross-sectional filling rate of the oval cross-section is 70% - 75%; During the selection process of the yoke structure, the selection is completed according to performance and price factors. The following formula is used to judge the cost performance parameter A of the selected yoke structure: A = p0 / xρ b ; Among them, p0 is the specific core loss of silicon steel sheet, with the unit of w / kg, which is determined by material parameters; x is the price, which is determined by the pricing at that time; ρ b is the cross-sectional filling ratio.

5. The method for designing a core structure optimized based on accessories according to claim 1, characterized in that The clamping structure includes steel plate clamps, bent clamps, temporary clamps, and channel steel clamps. The type of the clamping structure is selected according to the following method: If a specified type of clamping structure is selected, mechanical simulation is required. If the type of the clamping structure is not specified, the selection is made after judging according to strength, accuracy, and cost factors in turn.

6. The core structure design method based on accessory optimization according to claim 1, wherein, The fasteners include metal fasteners and non-metal fasteners. The metal fasteners and non-metal fasteners are selected according to the tension strength and the sizes of the process holes and the through holes.

7. A core structure design system based on accessory optimization, characterized in that, Including a process hole and a through-hole design module, an iron loss performance design module, a yoke structure design module, and a clamping structure and fastener design module, the accessory-optimized iron core structure design method according to any one of claims 1-6 completes the accessory-optimized design of the iron core structure through the process hole and through-hole design module, the iron loss performance design module, the yoke structure design module, and the clamping structure and fastener design module.

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