A method for manufacturing stacked soft magnetic bodies

Abstract

The invention discloses a manufacturing method for stacking soft magnetic bodies, comprising the following steps: step S1: dividing silicon steel sheets into X parts according to the fan-shaped cross-sectional area between the outer diameter and the inner diameter, and stacking silicon steel sheets of different widths in each part according to a stacking algorithm to form a fan-shaped silicon steel sheet group; step S2: manufacturing an iron barrel tooling; step S3: slicing the silicon steel sheets according to the length of the iron barrel tooling, and then inserting each fan-shaped silicon steel sheet group in sequence between the iron barrel workpiece and the core rod by combining the iron barrel tooling and a core rod, and stacking to form a cylindrical iron core; the invention provides a manufacturing method for stacking soft magnetic bodies, using ultra-thin silicon steel sheets with a minimum thickness of 0.04 mm and low eddy current loss. At the same time, in the structure of the invention, the magnetic flux is parallel to the plane of the silicon steel sheets, thereby increasing the stacking coefficient of the soft magnetic body and further reducing the eddy current loss.

Description

Technical Field

[0001] The invention relates to the technical field of transformer processing and manufacturing, and in particular to a manufacturing method for stacked soft magnetic bodies. Background Art

[0002] At present, in the process of electric energy transmission, a relatively low voltage is first obtained through a generator, and then a transformer is used to step up the voltage at the transmission end of the power plant to obtain a higher transmission voltage. After long-distance transmission, a transformer is used to step down the voltage to an appropriate range at the step-down end in the power consumption area.

[0003] The iron core used in the existing transformer is stacked by punching sheets. The thickness of the non-oriented silicon steel sheet used is between 0.35 and 0.5 mm, and the lamination coefficient is between 0.9 and 0.97, which means the relative eddy current loss is relatively high. Under working conditions, the higher the eddy current loss, the higher the temperature rise will be, affecting the working efficiency. The thickness of the silicon steel sheet is an important factor affecting the eddy current loss. The greater the thickness, the higher the eddy current loss.

[0004] Based on the above situation, the present invention proposes a manufacturing method for stacked soft magnetic bodies, which can effectively solve the above problems. Summary of the invention

[0005] The purpose of the present invention is to provide a manufacturing method for stacking soft magnetic bodies. The present invention provides a manufacturing method for stacking soft magnetic bodies, which uses ultra-thin silicon steel sheets with a minimum thickness of 0.04 mm and low eddy current loss. At the same time, in the structure of the present invention, the magnetic flux is parallel to the plane of the silicon steel sheet, which increases the lamination factor of the soft magnetic body and further reduces the eddy current loss.

[0006] The present invention is achieved through the following technical solutions:

[0007] A method for manufacturing stacked soft magnetic bodies, comprising the following steps:

[0008] Step S1: Divide the silicon steel sheet into X parts according to the fan-shaped cross-sectional area between the outer diameter and the inner diameter, and stack silicon steel sheets of different widths in each part according to a stacking algorithm to form a fan-shaped silicon steel sheet group;

[0009] Step S2: manufacturing iron barrel tooling;

[0010] Step S3: Slice the silicon steel sheet according to the length of the iron barrel tooling, and then insert each sector-shaped silicon steel sheet group into the space between the iron barrel tooling and the core rod by combining the iron barrel tooling and the core rod, and stack them to form a cylindrical iron core;

[0011] Step S4: curing the silicon steel sheet with self-adhesive function in the cylindrical iron core by heating and pressurizing equipment;

[0012] Step S5: removing the iron barrel tooling and polishing the surface of the cylindrical iron core;

[0013] Step S6: Covering the two ends of the cylindrical core with a front cover and a rear cover to form a complete stacked soft magnetic body.

[0014] According to the above technical solution, as a further preferred technical solution of the above technical solution, in step S1, the lamination algorithm specifically includes the following steps:

[0015] Step S1.1: Determine the outer circle diameter W and the inner circle diameter N, and set the outer circle and the inner circle to have the same center;

[0016] Step S1.2: Determine the vertical distance V between the outer circle and the inner circle;

[0017] Step S1.3: Determine the maximum width MAX and the thickness H of the silicon steel sheet according to the outer diameter W, the inner diameter N and the vertical distance V;

[0018] Step S1.4: Determine the number A of silicon steel sheets of the first width, the number B of silicon steel sheets of the second width, the number C of silicon steel sheets of the third width, the number D of silicon steel sheets of the fourth width, the number E of silicon steel sheets of the fifth width, the number F of silicon steel sheets of the sixth width, the number G of silicon steel sheets of the seventh width, and the total number ALL of silicon steel sheets according to the widest width MAX and the thickness H of the silicon steel sheets;

[0019] Step S1.5: The number of silicon steel sheets with remainders is increased by allocating them within each Q group to determine the number X of silicon steel sheet combinations.

[0020] According to the above technical solution, as a further preferred technical solution of the above technical solution, the thickness of the silicon steel sheet is 0.1 mm, 0.08 mm or 0.04 mm.

[0021] According to the above technical solution, as a further preferred technical solution of the above technical solution, in step S2, the iron barrel tooling is in a circular ring shape, and the inner diameter is equal to the outer diameter W of the sector-shaped silicon steel sheet group.

[0022] According to the above technical solution, as a further preferred technical solution of the above technical solution, in step S4, the heating temperature is 200°C, the insulation time is 1h, and the pressure is 2N / mm 2 .

[0023] According to the above technical solution, as a further preferred technical solution of the above technical solution, in step S5, the polishing method is to manually polish and grind the surface of the cylindrical core with P400~P600 sandpaper until the polishing reaches a bright surface effect.

[0024] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0025] The present invention provides a manufacturing method for stacking soft magnetic bodies, which uses ultra-thin silicon steel sheets with a minimum thickness of 0.04 mm and low eddy current loss. At the same time, in the structure of the present invention, the magnetic flux is parallel to the plane of the silicon steel sheets, which increases the stacking factor of the soft magnetic body and further reduces the eddy current loss. DETAILED DESCRIPTION

[0026] In order to enable those skilled in the art to better understand the technical solution of the present invention, the preferred implementation scheme of the present invention is described below in conjunction with specific examples.

[0027] A method for manufacturing stacked soft magnetic bodies, comprising the following steps:

[0028] Step S1: Divide the silicon steel sheet into X parts according to the fan-shaped cross-sectional area between the outer diameter and the inner diameter, and stack silicon steel sheets of different widths in each part according to a stacking algorithm to form a fan-shaped silicon steel sheet group;

[0029] Step S2: manufacturing iron barrel tooling;

[0030] Step S3: Slice the silicon steel sheet according to the length of the iron barrel tooling, and then insert each sector-shaped silicon steel sheet group into the space between the iron barrel tooling and the core rod by combining the iron barrel tooling and the core rod, and stack them to form a cylindrical iron core;

[0031] Step S4: curing the silicon steel sheet with self-adhesive function in the cylindrical iron core by heating and pressurizing equipment;

[0032] Step S5: removing the iron barrel tooling and polishing the surface of the cylindrical iron core;

[0033] Step S6: Covering the two ends of the cylindrical core with a front cover and a rear cover to form a complete stacked soft magnetic body.

[0034] The present invention adopts ultra-thin silicon steel sheets with a minimum thickness of 0.04 mm and low eddy current loss. Meanwhile, in the structure of the present invention, the magnetic flux is parallel to the plane of the silicon steel sheets, which increases the lamination factor of the soft magnetic body and further reduces the eddy current loss.

[0035] Further, in another embodiment, in step S1, the lamination algorithm specifically includes the following steps:

[0036] Step S1.1: Determine the outer circle diameter W and the inner circle diameter N, and set the outer circle and the inner circle to have the same center;

[0037] Step S1.2: Determine the vertical distance V between the outer circle and the inner circle;

[0038] Step S1.3: Determine the maximum width MAX and the thickness H of the silicon steel sheet according to the outer diameter W, the inner diameter N and the vertical distance V;

[0039] Step S1.4: Determine the number A of silicon steel sheets of the first width, the number B of silicon steel sheets of the second width, the number C of silicon steel sheets of the third width, the number D of silicon steel sheets of the fourth width, the number E of silicon steel sheets of the fifth width, the number F of silicon steel sheets of the sixth width, the number G of silicon steel sheets of the seventh width, and the total number ALL of silicon steel sheets according to the widest width MAX and the thickness H of the silicon steel sheets;

[0040] Step S1.5: The number of silicon steel sheets with remainders is increased by allocating them within each Q group to determine the number X of silicon steel sheet combinations.

[0041] Preferably, W=180mm, N=80mm, V=50mm, MAX=50mm, H=0.08mm, first width=50mm, second width=42mm, third width=34mm, fourth width=29mm, fifth width=24mm, sixth width=19mm, seventh width=10mm, A=8.6, B=2, C=2, D=2, E=2, F=2, G=1, ALL=19.6, Q=10, X=360.

[0042] Furthermore, in another embodiment, the thickness of the silicon steel sheet is 0.1 mm, 0.08 mm or 0.04 mm.

[0043] Specifically, when the outer diameter is 180mm and the inner diameter is 80mm, the two circles have the same center, and the vertical distance between the two circular surfaces is 50mm, so the widest silicon steel sheet is 50mm. When a silicon steel sheet with a thickness of 0.08mm is selected and divided into 360 parts, the inner arc length of each part is N*π / X=0.698mm, and the outer arc length is W*π / X≈1.572mm. It can be obtained that the total number of silicon steel sheets is 1.572 / H=19.6 sheets, of which the number of 50mm wide silicon steel sheets is 8.6 sheets (i.e. 0.698 / H≈8.6), the number of 42mm wide silicon steel sheets is 2 sheets, and the number of 34mm wide silicon steel sheets is 2 sheets. There are 2 silicon steel sheets with a width of 29mm, 2 silicon steel sheets with a width of 24mm, 2 silicon steel sheets with a width of 19mm, and 1 silicon steel sheet with a width of 10mm. Since there are 8.6 silicon steel sheets with a width of 50mm and there are gaps at the outer circle, silicon steel sheets of the second width, the third width, the fourth width, the fifth width, the sixth width, and the seventh width are required to be embedded in the outer circumference to ensure that each silicon steel sheet group is fan-shaped; and the number of sheets with remainders (i.e. silicon steel sheets of the first width) is increased by allocating them within every 10 portions, so that a total of 360 fan-shaped silicon steel sheet groups can be prepared for even distribution.

[0044] Furthermore, in another embodiment, in step S2, the iron barrel tooling is in a circular ring shape, and the inner diameter is equal to the outer diameter W of the sector-shaped silicon steel sheet group.

[0045] Furthermore, in another embodiment, in step S4, the heating temperature is 200°C, the insulation time is 1 hour, and the pressure is 2N / mm 2 .

[0046] Furthermore, in another embodiment, in step S5, the polishing treatment is performed by manually polishing the surface of the cylindrical core with P400-P600 sandpaper until a bright surface effect is achieved.

[0047] Unless otherwise specified, in the present invention, the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicating orientation or positional relationships are based on the orientation or positional relationships shown in the drawings, which are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, the terms describing the orientation or positional relationship in the present invention are only used for illustrative purposes and cannot be understood as limitations on this patent. For ordinary technicians in this field, the specific meanings of the above terms can be understood in conjunction with the drawings and according to specific circumstances.

[0048] Unless otherwise clearly specified and limited, in the present invention, the terms "disposed", "connected" and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected, or indirectly connected through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0049] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Any simple modification or equivalent change made to the above embodiment based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. A method for manufacturing stacked soft magnetic bodies, characterized in that: The following steps are involved: Step S1: Divide the silicon steel sheet into X parts according to the fan-shaped cross-sectional area between the outer diameter and the inner diameter, and stack silicon steel sheets of different widths in each part according to a stacking algorithm to form a fan-shaped silicon steel sheet group; wherein the thickness of the silicon steel sheet is 0.1 mm, 0.08 mm or 0.04 mm; The lamination algorithm specifically comprises the following steps: Step S1.1: Determine the outer circle diameter W and the inner circle diameter N, and set the outer circle and the inner circle to have the same center; Step S1.2: Determine the vertical distance V between the outer circle and the inner circle; Step S1.3: Determine the maximum width MAX and the thickness H of the silicon steel sheet according to the outer diameter W, the inner diameter N and the vertical distance V; Step S1.4: Determine the number A of silicon steel sheets of the first width, the number B of silicon steel sheets of the second width, the number C of silicon steel sheets of the third width, the number D of silicon steel sheets of the fourth width, the number E of silicon steel sheets of the fifth width, the number F of silicon steel sheets of the sixth width, the number G of silicon steel sheets of the seventh width, and the total number ALL of silicon steel sheets according to the inner arc length, the outer arc length and the thickness H; Step S1.5: The number of silicon steel sheets with remainder is increased by allocating it within each Q group to determine the number X of silicon steel sheet combinations; Step S2: manufacturing iron barrel tooling; Step S3: Slice the silicon steel sheets according to the length of the iron barrel tooling, and then insert each sector-shaped silicon steel sheet group into the iron barrel tooling and the core rod in sequence by combining the iron barrel tooling and the core rod, and stack them to form a cylindrical iron core; Step S4: curing the silicon steel sheet with self-adhesive function in the cylindrical iron core by heating and pressurizing equipment; Step S5: removing the iron barrel tooling and polishing the surface of the cylindrical iron core; Step S6: Covering the two ends of the cylindrical core with a front cover and a rear cover to form a complete stacked soft magnetic body.

2. A method for manufacturing stacked soft magnetic bodies according to claim 1, characterized in that: In step S2, the iron barrel tooling is in a circular ring shape, and the inner diameter is equal to the outer diameter W of the sector-shaped silicon steel sheet group.

3. A method for manufacturing stacked soft magnetic bodies according to claim 1, characterized in that: In step S4, the heating temperature is 200°C, the insulation time is 1h, and the pressure is 2N / mm 2 .

4. A method for manufacturing stacked soft magnetic bodies according to claim 1, characterized in that: In step S5, the polishing treatment is performed by manually polishing the surface of the cylindrical core with P400-P600 sandpaper until a bright surface effect is achieved.