Analytic model of three-dimensional wound core winding process

Abstract

The invention relates to an analytical model for a three-dimensional wound core winding process, which is used for accurately analyzing the influence of winding process parameters on no-load loss, and is characterized in that the analytical model (K) for the three-dimensional wound core winding process is decomposed into two main modules according to winding process influence factors, the two modules comprise a winding radius influence module Kr and a winding tension influence module Kp, K = (Kr + Kp) / 100, and Kr is the winding radius influence module (coefficient); kp is a winding tension influence module (coefficient); r is the winding radius of the wound core, and p is the winding tension. According to the method, the influence factors influencing the three-dimensional wound core winding process are analyzed and calculated, the precise control model is established, the technological level of the three-dimensional wound core winding process is improved, the wound core performance is improved, and cost is reduced and efficiency is improved. According to the method, how the analysis value of the influence is applied to the determination of the process coefficient of the heat-resistant oriented silicon steel three-dimensional wound core can be determined.

Description

Technical Field

[0001] The present invention belongs to the field of transformer core production and manufacturing, and relates to a three-dimensional wound core winding process analytical model, specifically to a heat-resistant oriented silicon steel three-dimensional wound core winding process analytical model and its application, and more specifically to a control model of a three-phase three-dimensional wound core distribution transformer core winding process using heat-resistant oriented silicon steel and its application. Background Art

[0002] Transformers are electric energy transmission equipment manufactured based on the principle of electromagnetic induction. The iron core, as the core component of the transformer, is known as the "heart of the transformer", and oriented silicon steel is the constituent material of the iron core. Heat-resistant annealable oriented silicon steel is the main material for three-dimensional wound cores. The manufacturing process of three-dimensional wound core transformer cores mainly includes several processes such as oriented silicon steel coil cutting, winding, assembly, annealing, and testing.

[0003] The no-load performance of a transformer is one of the most important performances of a transformer. In the traditional calculation of no-load loss of a transformer, the influences of the above processes are all attributed to a coefficient K, which reflects the change in the unit loss of silicon steel sheets caused by the core structure or processing factors, called the core process coefficient. The specific formula is as follows:

[0004] P0=K*G tx *P tx (W)

[0005] P0: Transformer no-load loss (W)

[0006] K: Core process coefficient

[0007] P tx : Unit iron loss (W / kg)

[0008] G tx :Core weight(kg)

[0009] It can be seen that the simple characterization of no-load loss is related to the above three aspects. However, there has been no detailed and accurate analysis of the proportion of each parameter, the deep impact of each parameter and their interaction.

[0010] In addition, specifically in the production process of the three-dimensional wound core transformer core, there will be influencing factors in multiple processes, which makes the core process coefficient actually fluctuate. How to establish a characterization of the core process coefficient based on the actual situation of the actual process, so that the calculation of iron loss is more accurate, and provide a more accurate basis for transformer manufacturers to analyze the iron loss during the actual operation of the subsequent motor and various actual related analyses; make the corresponding analysis more accurate and able to point to the real problem

[0011] In addition, the parameters and some influencing factors in the winding process of the three-dimensional wound core also have a great influence on the core process coefficient. However, there was a lack of specific research on this in the past, resulting in the fact that the parameters and some influencing factors in the winding process of the three-dimensional wound core (for example, the winding radius and winding tensile stress of the core winding) have not been taken seriously in terms of their influence on the no-load loss.

[0012] The invention application with patent number: CN201610968298.4 discloses "a control model for transformer core process coefficient". The transformer core production process coefficient K' is decomposed into 5 sub-coefficients according to each process: stacking influence sub-coefficient K'1, longitudinal shear influence sub-coefficient K'2, transverse shear influence sub-coefficient K'3, core structure influence sub-coefficient K'4 and burr influence sub-coefficient K'5; the control model of the core process coefficient K is as follows: K'=(1+K'5)×(1+K'1+K'2+K'3+K'4); the core adopts oriented silicon steel.

[0013] The invention application with patent number: CN201610231782.9 discloses "a transformer core section design method based on particle swarm optimization". First, the core number is determined according to the corresponding relationship between the transformer core diameter and the core number, and pre-processing is performed for the subsequent optimization of the stack thickness of each level. Then, the particle swarm optimization algorithm is applied to optimize and solve the stack thickness of each level, and then the final optimized design scheme is obtained.

[0014] The invention application with patent number: CN202110589061.6 discloses "a method for evaluating the quality of an ultra-thin silicon steel core for a DC converter valve saturated reactor", including the following steps: S1, appearance evaluation; S2, stacking coefficient evaluation; S3, magnetic property evaluation; S4, noise evaluation; S5, environmental temperature change tolerance evaluation and S6, long-term operation performance evaluation. The present invention takes into account the DC converter valve saturated reactor's requirements for the appearance, stacking coefficient, magnetic property, noise and long-term operation of the ultra-thin silicon steel core, and realizes the performance evaluation of the appearance of the ultra-thin silicon steel core, the evaluation of the basic parameters of the core, the electromagnetic performance evaluation, the evaluation of the tolerance to environmental temperature changes and the long-term electrothermal operation characteristics evaluation, which provides a guarantee for the reliable operation of the ultra-thin silicon steel core for the DC converter valve saturated reactor.

[0015] However, the above-mentioned authorized patent does not study the influence of the parameters of the winding process (for example, the winding radius and the winding tensile stress of the core winding) and some existing factors on the core process coefficient in the important process of the three-dimensional wound core. In this way, there is a lack of specific research on the parameters and some existing influencing factors in the important process of the winding process (for example, the winding radius and the winding tensile stress of the core winding) of the three-dimensional wound core.

[0016] In the past, when considering the influence of parameters such as the winding radius and winding tensile stress during core winding and some related factors on the core process coefficient, the parameter value range of the influence of tensile stress in the winding process on iron loss is often set based on experience according to the core winding capacity and the size of the product winding radius.

[0017] However, the above previous experience is not very accurate. In the past, when winding the core, people generally only paid attention to the final experimental results of the core, and did not analyze the intermediate process, resulting in the fact that the parameters and some influencing factors in the important process of three-dimensional winding core winding technology (for example, the winding radius and winding tensile stress of the core winding) and the influence of some influencing factors on the no-load loss were not taken seriously.

[0018] On the other hand, the winding process of the three-dimensional wound core is the process that produces the greatest additional stress on the oriented silicon steel raw material. In particular, the core winding process of the three-phase three-dimensional wound core distribution transformer made of heat-resistant oriented silicon steel does have a greater impact on the no-load loss, resulting in the greatest impact on the performance changes of the material in this process.

[0019] The present invention focuses on analyzing the parameters and influencing factors in the winding process of the important process of the three-dimensional wound core, and based on this, establishes a process quality control model for the winding process of the heat-resistant oriented silicon steel three-dimensional wound core distribution transformer core, so as to more accurately analyze the influence of the winding process on the performance of the oriented silicon steel material. Through precise positioning analysis, the influence of the winding process parameters on the no-load loss is accurately analyzed, so as to provide transformer manufacturers with better control of the winding process quality of the three-dimensional wound core, improve product performance and reduce costs. Summary of the invention

[0020] To solve the above problems, the purpose of the present invention is to establish an analytical model of the winding process of a three-dimensional wound core and its application, in particular, to establish a process quality control model for the winding process of a heat-resistant oriented silicon steel three-dimensional wound core distribution transformer core, so as to more accurately analyze the influence of the winding process on the performance of oriented silicon steel materials. Through precise positioning analysis, the influence of winding process parameters on no-load loss is accurately analyzed, so as to better control the quality of the three-dimensional wound core winding process, improve product performance and reduce costs.

[0021] The technical solution of the present invention is as follows:

[0022] An analytical model for the winding process of a three-dimensional wound core, the analytical model is used to accurately analyze the influence of winding process parameters on no-load loss, and is characterized by:

[0023] The analytical model of the winding process of the three-dimensional wound core is decomposed into two main modules according to the influencing factors of the winding process, namely the winding radius influencing module Kr and the winding tension influencing module Kp:

[0024] K=(Kr+Kp) / 100

[0025] in,

[0026] K: Analytical model of the three-dimensional wound core winding process (%);

[0027] Kr: Three-dimensional coil core winding radius influence module (coefficient);

[0028] Kp: Three-dimensional coil core winding tension influence module (coefficient).

[0029] According to the analytical model of the three-dimensional wound core winding process of the present invention, it is characterized by:

[0030] Kr=132-21.5Ln(r)

[0031] in,

[0032] r: The winding radius of the three-dimensional coiled core.

[0033] According to the analytical model of the three-dimensional wound core winding process of the present invention, it is characterized by:

[0034] in,

[0035] r: winding radius of three-dimensional coil core, 20 <r<500mm。

[0036] According to the analytical model of the three-dimensional wound core winding process of the present invention, it is characterized by:

[0037] Kp=17.4P 2 -20P+7

[0038] in,

[0039] P: Three-dimensional coil core winding tension, MPa.

[0040] According to the analytical model of the three-dimensional wound core winding process of the present invention, it is characterized by:

[0041] in,

[0042] P=0-1.

[0043] According to the analytical model of the three-dimensional wound core winding process of the present invention, it is characterized by:

[0044] in,

[0045] P=0.2-0.6.

[0046] According to the analytical model of the three-dimensional wound core winding process of the present invention, it is characterized by:

[0047] in,

[0048] r: winding radius of three-dimensional coil core, 50 <r<500mm。

[0049] According to the analytical model of the three-dimensional wound core winding process of the present invention, it is characterized by:

[0050] The three-dimensional wound core is a heat-resistant oriented silicon steel three-dimensional wound core.

[0051] According to the analytical model of the three-dimensional wound core winding process of the present invention, it is characterized by:

[0052] K=9.33~31.04.

[0053] The first step in transformer design is to select the core diameter. Products of different capacities have different core diameters. For three-dimensional wound cores, this means that the winding radius of the core winding is different. Large-capacity products have a large winding radius, while small-capacity products have a small winding radius. Different winding radii directly affect the performance of oriented silicon steel, and thus affect the no-load loss performance of the transformer.

[0054] According to the analytical model of the winding process of a heat-resistant oriented silicon steel three-dimensional wound core of the present invention, the winding radius has a great influence on the winding performance. The influence is particularly large when the winding radius is within the range of 50 to 300. When the winding radius is between 300 and 500, the influence begins to decrease, and there is basically no influence above 500. Therefore, increasing the winding radius within the range of 50 to 300 can quickly reduce the winding process coefficient.

[0055] According to the analytical model of the winding process of a heat-resistant oriented silicon steel three-dimensional wound core described in the present invention,

[0056] Under the condition of the same winding radius, a relatively good winding process coefficient can be obtained when the winding tension is in the range of 0.2 to 0.6.

[0057] According to the analytical model of the winding process of a heat-resistant oriented silicon steel three-dimensional wound core of the present invention,

[0058] Since the winding radius has a great influence on the winding performance, the winding radius can be reasonably set within an appropriate range for products with the same capacity. Generally, it can be adjusted within the range of + / -30% of the winding radius. If the winding radius is particularly small, the winding radius adjustment can be designed according to +30%.

[0059] According to the analytical model of the winding process of a heat-resistant oriented silicon steel three-dimensional wound core of the present invention, each module factor and its variable has a certain range of values. The influencing factors in the winding process of the three-phase distribution transformer core with a three-dimensional wound core are shown in the following table in combination with the range of values.

[0060] According to different winding radii and winding tensions, a variety of different cores are made, and the coefficient of change of core loss relative to the original performance of oriented silicon steel is tested. The relationship between core performance and tension and radius is summarized, and a model is established.

[0061] Process module Value range kr 20<r<500 Kp 0<P<1

[0062] Beneficial effects of the present invention

[0063] The process quality control model of the heat-resistant oriented silicon steel three-dimensional wound core distribution transformer core winding process of the present invention can accurately analyze the influence of the winding process on the performance of oriented silicon steel materials. Through accurate positioning analysis, transformer manufacturers can better control the three-dimensional wound core winding process quality, improve product performance, reduce costs, and achieve lean production. DETAILED DESCRIPTION

[0064] Embodiment 1:

[0065] Table 1 below shows the design of winding process parameters and the no-load loss test results after winding of the core of a distribution transformer produced by a domestic three-dimensional wound core manufacturer. Based on these data and the analytical model of the present invention, the model coefficient of the winding process can be calculated. Among them, the same capacity product and the same winding radius are used, but the winding tension is different.

[0066] Table 1

[0067]

[0068] It can be seen from the above table that under the condition of the same winding radius, a relatively good winding process coefficient can be obtained when the winding tension is in the range of 0.2 to 0.6.

[0069] Example 2

[0070] Table 2 below shows the design of winding process parameters and the no-load loss test results after winding of the core of a distribution transformer produced by a domestic three-dimensional wound core manufacturer. Based on these data and the analytical model of the present invention, the model coefficient of the winding process can be calculated. Among them, different capacity products and different winding radii are used, but the winding tension is the same.

[0071] Table 2

[0072]

[0073]

[0074] It can be seen from the above table that the winding radius has a great influence on the winding performance. Increasing the winding radius can quickly reduce the winding coefficient.

[0075] Example 3

[0076] Table 3 below shows the design of winding process parameters and the no-load loss test results after winding of the core of a distribution transformer produced by a domestic three-dimensional wound core manufacturer. Based on these data and the analytical model of the present invention, the model coefficient of the winding process can be calculated. Among them, different winding radii are used, but the capacity product and winding tension are the same.

[0077] Table 3

[0078]

[0079] It can be seen from the above table that the winding radius has a great influence on the winding performance. For products with the same capacity, the winding radius can be adjusted within an appropriate range to reduce the winding process coefficient.

[0080] It can be seen from the above embodiments that the winding process model is established according to the winding process factors, and the winding influence factor K of the entire core is calculated, which is very close to the core winding process coefficient obtained by reverse deduction of the test results, and the model calculation results are accurate.

[0081] It can be seen from the above embodiments that the analytical model of this invention can analyze the influence of the quality of the core winding process on the no-load performance of the core, which is convenient for core manufacturers to adjust the process parameters of the three-dimensional core winding process in advance, which is beneficial for manufacturers to reduce costs and increase efficiency.

[0082] According to the present invention, starting from the important core winding production process of three-dimensional wound core transformer, the factors of core performance in the process are analyzed, and an analytical model is established, breaking the traditional empirical control coefficient method, so that transformer factories can accurately improve quality, reduce costs and increase efficiency, and have excellent practicality and promotion.

Claims

1. An analytical model of the winding process of a three-dimensional wound core, the analytical model is used to accurately analyze the influence of winding process parameters on no-load loss, characterized in that: The analytical model of the winding process of the three-dimensional wound core is decomposed into two main modules according to the influencing factors of the winding process, namely the winding radius influencing module Kr and the winding tension influencing module Kp: K=(Kr+Kp) / 100 in, K: Analytical model of the three-dimensional wound core winding process (%); Kr: Three-dimensional coil core winding radius influence module (coefficient); Kp: Three-dimensional coil core winding tension influence module (coefficient).

2. The analytical model (K) of the three-dimensional wound core winding process according to claim 1, characterized in that: Kr=132-21.5Ln(r) in, r: The winding radius of the three-dimensional coiled core.

3. The analytical model (K) of the three-dimensional wound core winding process according to claim 1, characterized in that: r: winding radius of three-dimensional coil core, 20 <r<500mm。 4. The analytical model of the winding process of a three-dimensional wound core as claimed in claim 1 (%), characterized in that: Kp=17.4P 2 -20P+7 P: Three-dimensional coil core winding tension, MPa.

5. The analytical model (%) of the winding process of a three-dimensional wound core according to claim 4, characterized in that: P＝0-1。 6. The analytical model (%) of the winding process of a three-dimensional wound core according to claim 5, characterized in that: P＝0.2-0.6。 7. The analytical model (%) of the winding process of a three-dimensional wound core as claimed in claim 3, characterized in that: r: winding radius of three-dimensional coil core, 50 <r<500mm。 8. The analytical model of the winding process of a three-dimensional wound core as claimed in claim 1 (%), characterized in that: The three-dimensional wound core is a heat-resistant oriented silicon steel three-dimensional wound core.

9. The analytical model of the winding process of a three-dimensional wound core as claimed in claim 1 (%), characterized in that as follows: K＝9.33～31.04。

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