Low-noise amorphous alloy transformer assembly process

Abstract

The invention provides a low-noise amorphous alloy transformer assembly process, relates to the technical field of transformer assembly, and solves the technical problem that an iron core is subjected to abnormal force due to assembly process defects in the prior art. The process comprises the following steps of: inserting iron cores, ensuring that gaps are reserved between the iron cores and the inner wall of a coil, inserting a middle iron core, and then inserting iron cores on two sides; after one layer of iron core is inserted, fragments are cleaned, every two adjacent iron cores are tightly supported by a paperboard, the iron cores are closed, and the paperboards are pulled out; when the number of the iron cores is at least two, the iron cores are sequentially inserted from bottom to top according to the method, and insulation treatment needs to be conducted on the top of each layer of iron core after insertion is completed. By adopting the process, the iron cores can be suspended on the coil after being mounted, the iron cores are only in contact with one end surface of the coil, the iron cores are not in contact with other parts of the coil, and the iron cores as well as the iron cores and the clamping pieces are not in contact, so that the noise is reduced by reducing the stress condition of the iron cores, changing the sound level propagation direction, increasing the radiation distance of sound waves along the surface and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of transformer assembly, in particular to an assembly process for a low-noise amorphous alloy transformer. Background Art

[0002] An amorphous alloy transformer is a transformer made of a new type of magnetic conductive material, amorphous alloy (soft magnetic material), as an iron core, which is combined with coils, clamps, oil tanks, etc. Due to the defects of the amorphous alloy iron core material itself, the sound pressure level and sound power level of the amorphous alloy transformer are relatively high (i.e., the noise is relatively high). In addition, the existing assembly process also has defects, which causes the amorphous alloy transformer to be noisy during operation. For example, in an amorphous alloy transformer assembled by the existing assembly process, the iron core contacts the coil, clamps or the iron core, generating stress, which leads to high noise during the operation of the product. Summary of the Invention

[0003] The present invention aims to provide a low-noise amorphous alloy transformer assembly process, resolving the technical problem of abnormal core stress caused by assembly process defects in the prior art. The various technical effects achieved by the preferred technical solution among the various technical solutions provided by the present invention are detailed below.

[0004] To achieve the above objectives, the present invention provides the following technical solutions:

[0005] The low-noise amorphous alloy transformer assembly process provided by the present invention includes:

[0006] The core is impregnated with transformer oil;

[0007] Lifting coils and measuring dimensions;

[0008] Fix the coil and assemble the insulation parts of the device body;

[0009] Lifting the core and clearing the debris;

[0010] When inserting the core, ensure that there is a gap between the core and the inner wall of the coil. Install the middle core first, then the cores on both sides. After inserting one layer of core, clean up the debris, use cardboard to hold the two adjacent cores tightly together, close the core, and remove the cardboard. Check whether there is a gap between the core and the coil or between the cores. If there is a gap between the core and the coil, or between the two adjacent cores, stop assembly, find out the cause, and reassemble.

[0011] When the core has at least two layers, install the cores from bottom to top in the same way as above. After each layer of core is installed, insulation treatment needs to be done on the top.

[0012] Insert the core grounding piece and lead out the core grounding wire;

[0013] Wrap the iron core, side columns and upper and lower iron yokes with adhesive tape and fix them firmly;

[0014] Assembly clamps;

[0015] Stand up the device and check the insulation resistance of the core.

[0016] Preferably, the core is inserted to ensure that there is a gap between the core and the inner wall of the coil, and the middle core is inserted first, and then the cores on both sides are inserted, which includes:

[0017] Insert the center column core, place the core opening into the U-shaped guide sleeve, adjust the height of the trolley table and the left and right deviation dimensions to leave a gap between the core and the inner wall of the low-voltage coil, remove any debris around the core and coil, and then use guide paper to slowly feed the core into the low-voltage coil insulation cylinder;

[0018] After the core is inserted into place, lower the height of the trolley table, withdraw the trolley, move the core to the correct position, and pull out the U-shaped guide sleeve and guide paper;

[0019] After the side column cores are assembled, the side column cores on both sides are sequentially inserted according to the middle column core insertion method.

[0020] Preferably, after a layer of cores is inserted, debris is cleaned, two adjacent cores are tightened with cardboard, the cores are closed, and the cardboard is pulled out, which includes:

[0021] Use magnetic tools to clean the debris generated during the core insertion process, use cardboard to hold the two adjacent cores tightly together, and restore the core sheets to a closed core in the order of the original bending direction. The overlap length of the core sheets should not be less than 8 mm. After the iron is closed, remove the cardboard.

[0022] After the iron is closed, put a rubber pad between the iron core and the silicon steel sheet, close the silicon steel sheet and ensure close contact with the rubber pad;

[0023] Stick tape with the same width as the core sheet at the joint.

[0024] Preferably, the core is impregnated with transformer oil, which includes lubricating the open end surface of the core to be used with transformer oil, leaving it for no less than fifteen minutes, and pasting adhesive tape on both end surfaces of the core at the non-opening portion.

[0025] Preferably, lifting the coil and measuring its dimensions include cleaning the body assembly platform, placing insulating cardboard on a "V"-shaped bracket, lifting the coil with a coil lifting tool, placing it flat on the "V"-shaped bracket, ensuring that the high-voltage outlet side faces downward, adjusting the platform height, measuring the inner and outer diameters of the coil, and recording the dimensional data.

[0026] Preferably, fixing the coil and assembling the body insulation comprises:

[0027] Install interphase insulation cardboard and side insulation cardboard;

[0028] Use a flat support plate to press against the end of the coil and lock it, then use the side pressure plate on the assembly table to press the coil tightly;

[0029] Use tape to stick the interphase insulating cardboard firmly, place paper troughs at both ends of the coil and fix them with tape, lay insulating cardboard inside the coil, and make sure the cardboard is higher than the coil leads.

[0030] Preferably, lifting the core and clearing debris include:

[0031] After the transformer oil is completely immersed in the amorphous alloy core sheets, use a suction cup to lift the amorphous alloy core onto the lifting trolley, and then use special tools to open the locking buckle on the top of the core. Then, open the amorphous alloy core sheets that are staggered and stacked at the opening in the order of the sets and clean up the debris.

[0032] Preferably, inserting the core grounding plate and leading out the core grounding wire comprises:

[0033] A grounding plate is inserted into each frame core. The insertion depth of the grounding plate is not less than 80 mm, and a groove for the grounding plate to extend out is opened on the insulating cardboard.

[0034] Preferably, raising the device body and detecting the insulation resistance of the core includes horizontally hanging the device body on a device body turning platform, turning it over after tightening, and detecting the insulation resistance of the core to ground.

[0035] This application adopts the above technical solution, which has at least the following beneficial effects:

[0036] A low-noise amorphous alloy transformer assembly process, comprising:

[0037] The core is impregnated with transformer oil;

[0038] Lifting coils and measuring dimensions;

[0039] Fix the coil and assemble the insulation parts of the device body;

[0040] Lifting the core and clearing the debris;

[0041] When inserting the core, ensure that there is a gap between the core and the inner wall of the coil. Install the middle core first, then the cores on both sides. After inserting one layer of core, clean up the debris, use cardboard to hold the two adjacent cores tightly together, close the core, and remove the cardboard. Check whether there is a gap between the core and the coil or between the cores. If there is a gap between the core and the coil, or between the two adjacent cores, stop assembly, find out the cause, and reassemble.

[0042] When the core has at least two layers, install the cores from bottom to top in the same way as above. After each layer of core is installed, insulation treatment needs to be done on the top.

[0043] Insert the core grounding piece and lead out the core grounding wire;

[0044] Wrap the iron core, side columns and upper and lower iron yokes with adhesive tape and fix them firmly;

[0045] Assembly clamps;

[0046] Stand up the device and check the insulation resistance of the core.

[0047] After assembly using the above process, the iron core is suspended on the coil. The iron core does not contact other parts of the coil, and there is no contact between the iron cores or between the iron cores and the clamps. This can reduce the stress on the iron core, change the direction of sound level propagation, and increase the surface radiation distance of sound waves to reduce noise.

[0048] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0050] Figure 1 This is a schematic diagram of the main structure of the amorphous alloy transformer provided by an embodiment of the present invention;

[0051] Figure 2 3D structural diagram of an amorphous alloy transformer provided by an embodiment of the present invention;

[0052] Figure 3 This is a schematic diagram of the structure of the insulation component of the coil assembly body provided by an embodiment of the present invention;

[0053] Figure 4 It is a schematic diagram of the core opening structure provided by an embodiment of the present invention.

[0054] In the figure, 1 is the iron core; 2 is the coil; 3 is the clamp; 4 is the interphase insulating cardboard; 5 is the side insulating cardboard. DETAILED DESCRIPTION

[0055] To make the objectives, technical solutions, and advantages of the present invention more apparent, the technical solutions of the present invention will be described in detail below. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other implementations obtained by those of ordinary skill in the art without inventive effort are within the scope of protection of the present invention.

[0056] A specific embodiment of the present invention provides a low-noise amorphous alloy transformer assembly process, comprising:

[0057] The core 1 is impregnated with transformer oil;

[0058] Lifting coil 2 and measuring dimensions;

[0059] Fix the coil 2 and assemble the insulation of the device body;

[0060] Lifting the core 1. Clean up the debris;

[0061] Insert the core 1, ensuring that there is a gap between the core 1 and the inner wall of the coil 2. Insert the middle core 1 first, then insert the cores 1 on both sides. After inserting one layer of core 1, clean up the debris, use cardboard to hold the two adjacent cores 1 tightly together, close the core 1, and remove the cardboard. Check whether there is a gap between the core 1 and the coil 2 or between the cores 1. If there is a gap between the core 1 and the coil 2, or between the two adjacent cores 1, stop assembly, find out the cause, and reassemble.

[0062] When the core 1 has at least two layers, the cores 1 are inserted from bottom to top in the same manner as above. After each layer of core 1 is inserted, insulation treatment needs to be performed on the top.

[0063] Insert the core 1 grounding piece and lead out the core 1 grounding wire;

[0064] Encapsulate the iron core 1, the side columns and the upper and lower iron yokes with adhesive tape, and fix them firmly;

[0065] Assembly clamp 3;

[0066] Stand up the device and check the insulation resistance of core 1.

[0067] After the above process is adopted, the core 1 is suspended on the coil 2. Figure 1 As shown in the figure, the core 1 contacts the end face of the top of the coil 2, while the core 1 does not contact the inner wall, outer wall and bottom end face of the coil 2. In addition, adjacent cores 1 are tightened with cardboard and then iron is combined, so that gaps are left between adjacent cores 1, and there is also a gap between the core 1 and the clamp 3. In this way, the core 1 is in a suspended state and other positions are not subjected to force, thereby reducing the force on the core 1, changing the sound level propagation direction and increasing the sound wave radiation distance along the surface to reduce noise.

[0068] In one embodiment of the present application, the low-noise amorphous alloy transformer assembly process is as follows:

[0069] The core 1 is immersed in transformer oil, including lubricating the open end face of the core 1 to be used with transformer oil, and the static time is not less than fifteen minutes. The core 1 is pasted with tape on both ends of the non-opening part. The lubrication position of the transformer oil is mainly at the corner position, and the tape can be 3M tape.

[0070] Lifting coil 2 and measuring its dimensions include cleaning the body assembly platform. First, clean the assembly platform with a vacuum cleaner, place insulating cardboard on the "V"-shaped bracket, and use the coil 2 lifting tool to lift coil 2. Place it flat on the "V"-shaped bracket, making sure that the high-voltage outlet side is facing downward, adjust the platform height, measure the inner and outer diameters of coil 2, and record the dimensional data. The dimensions of coil 2 must meet the requirements of the drawing and cannot be negative deviations.

[0071] The fixed coil 2 and the assembly body insulation parts include:

[0072] Install interphase insulation cardboard 4 and side insulation cardboard 5;

[0073] Use a flat support plate to press against the end of coil 2 and lock it, then use the side pressure plate on the assembly table to press coil 2 tightly;

[0074] Use tape to firmly stick the interphase insulating cardboard 4, place the paper slots on both ends of the coil 2 and fix them with tape, and lay the insulating cardboard inside the coil 2, with the cardboard higher than the leads of the coil 2;

[0075] Measure the transverse geometric dimensions of the three coils to see if they meet the requirements. Negative deviation is not allowed.

[0076] Lifting the iron core 1. Cleaning the debris includes:

[0077] After the transformer oil is completely immersed in the amorphous alloy core 1, use the suction cup to lift the amorphous alloy core 1 to the lifting trolley, and then use special tools to open the locking buckle on the top of the core 1, and then open the amorphous alloy core 1 that is staggered and stacked at the opening in the order of the set, and clean up the debris, as shown in the attached Figure 4 As shown in .

[0078] Core 1 insert includes:

[0079] Insert the center column core 1 and place the opening of the core 1 into the U-shaped guide sleeve. Since the core 1 is composed of multiple layers of patches, and an opening is opened at one end of the core, the multi-layer core is restricted by the U-shaped guide sleeve to ensure normal insertion. Adjust the height of the lifting trolley table and the left and right deviation dimensions to leave a gap between the core 1 and the inner wall of the low-voltage coil 2. This ensures that the core 1 will not contact the inner and outer walls of the coil 2 after insertion. Clear any debris around the core 1 and coil 2, and then use guide paper to slowly feed the core 1 into the insulation tube of the low-voltage coil 2.

[0080] After the core 1 is inserted into place, lower the height of the lifting trolley, withdraw the lifting trolley, then move the core 1 to the correct position, and pull out the U-shaped guide sleeve and guide paper;

[0081] After the side column core 1 is assembled, the side column cores 1 on both sides are inserted in the same way as the center column core 1.

[0082] Use a magnetic tool to clean the debris generated during the insertion of the core 1. Use cardboard to hold the two adjacent cores 1 tightly together. After the installation is completed, a gap is formed between the two adjacent cores 1. The core 1 is bent in its original direction and the core 1 pieces are restored to form a closed core 1 in the order of the sleeves. The overlap length of the core pieces is not less than 8 mm. The core pieces are tightly attached and no gaps are allowed. After the iron is closed, remove the cardboard.

[0083] After the iron is closed, place a rubber pad between the iron core 1 and the silicon steel sheet, close the silicon steel sheet, and ensure close contact with the rubber pad;

[0084] Stick a piece of tape as wide as the sheet width at the joint to prevent the core sheet from rebounding. During the operation, be careful to handle it with care to reduce the generation of debris and avoid the debris splashing into coil 2.

[0085] Insert the core grounding plate and lead out the core grounding wire including:

[0086] A grounding piece is inserted into each frame core 1, and the insertion depth of the grounding piece is not less than 80 mm. A slot for the grounding piece to extend out is provided on the insulating paper board.

[0087] Wrap the iron core, side columns and upper and lower iron yokes with a layer of 0.25mm thick adhesive paper and fix them with 3M tape.

[0088] Assembly clamps.

[0089] Lift the unit and test the insulation resistance of core 1. This involves hoisting the unit horizontally onto a turning platform, tightening it, and then turning it over. Test the insulation resistance of core 1 to ground using a 500V megger. The resistance must be ≥ 5MΩ.

[0090] In a specific embodiment of the present application, the iron core is provided with two layers. In practice, the lower iron core is inserted first, and after the iron bonding is completed, insulating paperboard is laid on the lower iron core, and then the upper iron core is inserted.

[0091] In the present invention, the terms "one embodiment," "some embodiments," "examples," "specific examples," "some examples," etc., mean that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and the features of different embodiments or examples without contradiction.

[0092] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present invention should be included in the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. A low-noise amorphous alloy transformer assembly process, characterized in that: include: The core is impregnated with transformer oil; Lifting coils and measuring dimensions; Fix the coil and assemble the insulation parts of the device body; Lifting the core and clearing the debris; When inserting the core, ensure that there is a gap between the core and the inner wall of the coil. Install the middle core first, then the cores on both sides. After inserting one layer of core, clean up the debris, use cardboard to hold the two adjacent cores tightly together, close the core, and remove the cardboard. Check whether there is a gap between the core and the coil or between the cores. If there is a gap between the core and the coil, or between the two adjacent cores, stop assembly, find out the cause, and reassemble. When the core has at least two layers, install the cores from bottom to top in the same way as above. After each layer of core is installed, insulation treatment needs to be done on the top. Insert the core grounding piece and lead out the core grounding wire; Wrap the iron core, side columns and upper and lower iron yokes with adhesive tape and fix them firmly; Assembly clamps; Stand up the device and check the insulation resistance of the core.

2. The low-noise amorphous alloy transformer assembly process according to claim 1, characterized in that: Insert the core to ensure there is a gap between the core and the inner wall of the coil. First insert the middle core, then insert the cores on both sides. Insert the center column core, place the core opening into the U-shaped guide sleeve, adjust the height of the trolley table and the left and right deviation dimensions to leave a gap between the core and the inner wall of the low-voltage coil, remove any debris around the core and coil, and then use guide paper to slowly feed the core into the low-voltage coil insulation cylinder; After the core is inserted into place, lower the height of the trolley table, withdraw the trolley, move the core to the correct position, and pull out the U-shaped guide sleeve and guide paper; After the side column cores are assembled, the side column cores on both sides are sequentially inserted according to the middle column core insertion method.

3. The low-noise amorphous alloy transformer assembly process according to claim 1, characterized in that: After a layer of cores is installed, clean up the debris, use cardboard to hold the two adjacent cores together, close the cores, and remove the cardboard including: Use magnetic tools to clean the debris generated during the core insertion process, use cardboard to hold the two adjacent cores tightly together, and restore the core sheets to a closed core in the order of the original bending direction. The overlap length of the core sheets should not be less than 8 mm. After the iron is closed, remove the cardboard. After the iron is closed, put a rubber pad between the iron core and the silicon steel sheet, close the silicon steel sheet and ensure close contact with the rubber pad; Stick tape with the same width as the core sheet at the joint.

4. The low-noise amorphous alloy transformer assembly process according to claim 1, characterized in that: The iron core is impregnated with transformer oil, which includes lubricating the open end face of the iron core to be used with transformer oil, leaving it for no less than fifteen minutes, and sticking tape on both end faces of the iron core at the non-opening part.

5. The low-noise amorphous alloy transformer assembly process according to claim 1, characterized in that: Lifting the coil and measuring its dimensions include cleaning the assembly platform, placing insulating cardboard on the "V"-shaped bracket, lifting the coil with a coil lifting tool, and placing it flat on the "V"-shaped bracket, ensuring that the high-voltage outlet side faces downward, adjusting the platform height, measuring the inner and outer diameters of the coil, and recording the dimensional data.

6. The low-noise amorphous alloy transformer assembly process according to claim 1, characterized in that: Fix the coil and assemble the body insulation parts including: Install interphase insulation cardboard and side insulation cardboard; Use a flat support plate to press against the end of the coil and lock it, then use the side pressure plate on the assembly table to press the coil tightly; Use tape to stick the interphase insulating cardboard firmly, place paper troughs at both ends of the coil and fix them with tape, lay insulating cardboard inside the coil, and make sure the cardboard is higher than the coil leads.

7. The low-noise amorphous alloy transformer assembly process according to claim 1, characterized in that: Lifting the core and clearing debris include: After the transformer oil is completely immersed in the amorphous alloy core sheets, use a suction cup to lift the amorphous alloy core onto the lifting trolley, and then use special tools to open the locking buckle on the top of the core. Then, open the amorphous alloy core sheets that are staggered and stacked at the opening in the order of the sets and clean up the debris.

8. The low-noise amorphous alloy transformer assembly process according to claim 1, characterized in that: Insert the core grounding plate and lead out the core grounding wire including: A grounding plate is inserted into each frame core. The insertion depth of the grounding plate is not less than 80 mm, and a groove for the grounding plate to extend out is opened on the insulating cardboard.

9. The low-noise amorphous alloy transformer assembly process according to claim 1, characterized in that: Lifting the device body and testing the core insulation resistance includes horizontally hanging the device body on the device body turning table, turning it over after tightening, and testing the core insulation resistance to ground.

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