Compact assembled three-dimensional transformer

Abstract

The application discloses a compact assembled three-dimensional transformer, which comprises a winding, a lead wire, a three-dimensional core, a clamp piece group and a pressing plate group, the clamp piece group and the pressing plate group are both provided with two groups, the three-dimensional core is assembled between the two clamp piece groups, the pressing plate group is assembled on the inner wall of the clamp piece group, the winding is arranged on the three-dimensional core and located between the two pressing plate groups, the lead wire is arranged on the winding, and the cross section shape of the core is a circular arc pentagon; the core column is designed, the cross section shape after splicing is a circular arc pentagon, and an inner plane and an outer plane are designed; compared with a circular core, the three-dimensional transformer can improve the space utilization rate, compared with a hexagonal core, the three-dimensional transformer can reduce material consumption, thereby reducing weight and volume, filling of the transformer is increased, consumption of conductive and magnetic materials is reduced, the internal structure of the transformer is more compact, the volume of the transformer is reduced, the transformer is beneficial to integration into a new energy system, and the overall integration degree of the system is improved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of transformers, and particularly provides a compact assembled three-dimensional transformer. BACKGROUND

[0002] With the vigorous development of new energy industry, as the key equipment for energy conversion and transmission, the performance and volume of transformers become the key factors restricting the efficiency and integration of new energy systems. The traditional planar structure transformer has limitations in energy density and volume, and is difficult to meet the demand of new energy systems for high efficiency and compactness. The iron core is set as a cylindrical structure, which is convenient for setting the winding, but due to the circular characteristics, the space utilization rate in the transformer is low, thereby making the volume of the transformer large. The iron core is set as a hexagonal prism structure, which can improve the utilization rate of the inside space of the iron core, but the overall volume of the transformer is still large, and the weight is large. Therefore, it is particularly important to develop a compact, light weight and small volume high efficiency transformer. SUMMARY

[0003] To solve the above problems, the application provides a compact assembled three-dimensional transformer.

[0004] To achieve the above purpose, the technical scheme adopted by the application is as follows: a compact assembled three-dimensional transformer, comprising a winding, a lead, a three-dimensional iron core, a clamp piece group and a pressing plate group, the clamp piece group and the pressing plate group are both two groups, the three-dimensional iron core is assembled between the two clamp piece groups, the pressing plate group is assembled on the inner wall of the clamp piece group, the winding is arranged on the three-dimensional iron core, and the winding is located between the two pressing plate groups, and the lead is arranged on the winding.

[0005] The three-dimensional iron core is composed of three single frame iron cores, the single frame iron core comprises an iron yoke frame and an iron core column, adjacent iron core columns are spliced to form an iron core, and the cross-sectional shape of the iron core is a circular arc pentagon, two iron core columns of the single frame iron core are symmetrically provided with an inner plane and an outer plane, the two inner planes are arranged in parallel, and the two outer planes are arranged in a coplanar manner.

[0006] Further, the included angle alpha of the two inner planes of the iron core is 120°, and the included angle beta of the inner plane and the outer plane of the iron core is 90°.

[0007] Further, the winding comprises a low-voltage winding and a high-voltage winding, the low-voltage winding is assembled on the iron core, and the high-voltage winding is assembled on the low-voltage winding, the low-voltage winding and the high-voltage winding are both provided with a lead, a low-voltage oil channel is arranged between adjacent low-voltage windings, a high-voltage oil channel is arranged between adjacent high-voltage windings, and a high-low voltage oil channel is arranged between the low-voltage winding and the high-voltage winding.

[0008] Further, the outermost layer of the high-voltage winding is wrapped with epoxy glass fiber without weft wrapping tape.

[0009] Further, the lead wire adopts a three-dimensional lead wire structure.

[0010] Further, insulating paper boards are arranged between adjacent core columns.

[0011] Further, the clamp group is in a triangular structure.

[0012] Further, the pressing plate group comprises winding pressing plates, iron yoke pressing plates and a center pressing plate, the winding pressing plates are respectively fixedly installed at three corners of the clamp group, the iron yoke pressing plates are respectively fixedly installed at three edges of the clamp group, the center pressing plate is fixedly installed at the center of the inner wall of the clamp group, and the inner end of the iron yoke pressing plate is attached to the side wall of the center pressing plate.

[0013] Further, the surfaces of the winding pressing plate, the iron yoke pressing plate and the center pressing plate towards the winding are all provided with flow guide grooves.

[0014] Further, the iron yoke pressing plate comprises an outer pressing plate and an inner pressing plate, and the outer pressing plate and the inner pressing plate form a T-shaped structure, the inner end of the inner pressing plate is attached to the side wall of the center pressing plate, the flow guide grooves of the outer pressing plate and the inner pressing plate are staggered and not connected to each other, and the flow guide groove of the inner pressing plate is connected to the flow guide groove of the center pressing plate.

[0015] The beneficial effects of the present application are:

[0016] The core column is designed in the present application, and the cross-sectional shape after splicing is a circular arc pentagon, and an inner plane and an outer plane are designed, which can improve the utilization rate of the internal space of the transformer compared with the circular core, can reduce material consumption compared with the hexagonal core, thereby reducing weight and volume, increasing the filling of the transformer, reducing the consumption of conductive and magnetic materials, finally making the internal structure of the transformer more compact, and reducing the volume of the transformer, which is beneficial to the integration of the transformer into the new energy system, and improves the overall integration of the system.

[0017] The flow guide grooves are arranged in the pressing plate group in the present application, which are used as oil channels, which is beneficial to the heat dissipation requirement of the transformer, and the flow guide grooves are staggered on the iron yoke pressing plate, different thermal convection zones are formed at the high-voltage winding and the low-voltage winding, which is beneficial to further improving the heat dissipation efficiency of the transformer, and is also helpful to make the structure more compact. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 It is a structural schematic diagram of the present application.

[0019] Figure 2 It is a front view of the present application. Figure 1

[0020] ​Figure 3 A-A direction in the present application Figure 2 A-A direction in the present application

[0021] Figure 4 A-A direction in the present application

[0022] Figure 5 A-A direction in the present application Figure 4 A-A direction in the present application

[0023] Figure 6 A-A direction in the present application Figure 5 A-A direction in the present application

[0024] Figure 7 A-A direction in the present application

[0025] Figure 8 A-A direction in the present application

[0026] Figure 9 A-A direction in the present application

[0027] The reference signs include: 1, winding, 101, low-voltage winding, 102, high-voltage winding, 2, lead, 3, three-dimensional iron core, 301, iron yoke frame, 302, iron core column, 3021, inner plane, 3022, outer plane, 3023, end plane, 303, insulating paper board, 4, clamp group, 5, pressing plate group, 501, winding pressing plate, 502, iron yoke pressing plate, 503, center pressing plate, 504, flow guide groove. DETAILED DESCRIPTION

[0028] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0029] Embodiment one

[0030] Referring to Figures 1 to 8 , a compact assembled three-dimensional transformer includes a winding 1, a lead 2, a three-dimensional iron core 3, a clamp group 4 and a pressing plate group 5. The clamp group 4 and the pressing plate group 5 are both two groups. The three-dimensional iron core 3 is assembled between the two clamp groups 4. The pressing plate group 5 is assembled on the inner wall of the clamp group 4. The winding 1 is arranged on the three-dimensional iron core 3, and the winding 1 is located between the two pressing plate groups 5. The lead 2 is arranged on the winding 1.

[0031] The winding 1, the lead 2, the three-dimensional iron core 3, the clamp group 4 and the pressing plate group 5 are all arranged in a transformer shell.

[0032] The clamp group 4 is used to fix the lead wire 2 and to position limit the pressing plate group 5 and the winding 1. As shown in Figure 1 、 Figure 4 and Figure 5 , the clamp group 4 is welded by channel steel, and the channel steel is provided with reinforcing ribs in the channel to increase the strength, expand the contact surface of the clamp group 4 and the pressing plate group 5, and ensure the stability when subjected to external force.

[0033] The pressing plate group 5 is used to position limit the winding 1. When the winding 1 is subjected to force along the axis of the core due to short circuit of the transformer, the pressing plate group 5 at both ends prevents the winding 1 from moving axially relative to the core, and the displacement between the two is limited by the insulating plate, thereby ensuring the stability of the winding 1 and the electrical connection parts connected to the winding 1.

[0034] The three-dimensional core 3 is composed of three single-frame cores. The single-frame core includes an iron yoke frame 301 and a core column 302. The adjacent core columns 302 are spliced to form a core, and the cross-sectional shape of the core is a circular-arc pentagon. The two core columns 302 of the single-frame core are symmetrically provided with inner planes 3021 and outer planes 3022 on the surfaces. The two inner planes 3021 are parallel, and the two outer planes 3022 are coplanar.

[0035] The shape of the circular-arc pentagon is a pentagon with angles arranged as circular arcs. Therefore, the shape of the core is a pentagonal prism, and each edge of the core is partially arranged as an arc surface.

[0036] The arc surface is designed to make the winding 1 more convenient to wind.

[0037] For the traditional circular cross-section core, the outer winding coil is also circularly arranged. The adjacent windings are arranged in a tangential manner, which makes the space in the transformer larger, thereby increasing the overall volume of the transformer and the amount and weight of the oil. In view of this situation, the parallel inner planes 3021 are designed to arrange the adjacent windings 1 in a face-to-face manner, thereby improving the space utilization and reducing the volume of the transformer and the amount of oil.

[0038] For the hexagonal cross-section core, although the inner side is provided with parallel planes, the outer side occupies a large space, which improves the space utilization in the middle of the transformer, but the space utilization around the transformer is very low. In view of this situation, the coplanar outer planes 3022 are designed to form a triangular shape with the outer planes 3022 of the three cores, thereby reducing the shape of the outer periphery of the transformer and simultaneously improving the space utilization around the transformer and reducing the volume of the transformer and the amount of oil.

[0039] Therefore, the overall volume of the transformer can be reduced, and the weight can be reduced.

[0040] Specifically, as shown inFigure 8 As shown, the included angle a of the two inner planes 3021 of the core is 120°, and the included angle b of the inner plane 3021 and the outer plane 3022 of the core is 90°.

[0041] Of the five faces of the core, two are inner planes 3021, two are outer planes 3022, and the last face, which faces outward, is an end plane 3023. According to the properties of a pentagon, the included angle q of the end plane 3023 and the outer plane 3022 is 120°.

[0042] In practice, due to the influence of production and other factors, the value of the included angle b of the inner plane 3021 and the outer plane 3022 may be affected, and thus the included angle b can be in the range of 85° to 95°, and the included angle b is 90° when the optimal performance parameters are reached.

[0043] As shown in Figure 3 and Figure 7 There is a recess on the end plane 3023, which is a phenomenon caused by process limitations. The actual length is much smaller than the length shown in the figure, and is approximately 10 mm to 15 mm, which has no effect on the performance of the core and the arrangement of the winding 1.

[0044] Setting the included angle a to 120° corresponds to three groups of cores, which can ensure that the inner planes 3021 are parallel to each other, and the winding 1 is arranged in parallel at the inner planes 3021, which can effectively improve the space utilization.

[0045] Setting the included angle b to 90° can ensure that the outer planes 3022 on the same side are coplanar, and the winding 1 can be arranged in parallel at the outer planes 3022, which reduces the use of space inside and outside the transformer by the winding 1, and thus the volume of the transformer shell can be reduced.

[0046] During the design of the size of the circular arc pentagon, the core cross-sectional shape and cross-sectional area size are directly affected, and according to the design manual of power transformers, the window height, window width, circle radius, straight line segment, coil structure size, wire cross section, wire length, resistance, weight calculation, and magnetic flux calculation also need to be considered. The change in the size of the circular arc pentagon will also affect and change the design of these parts, and the no-load loss, no-load current, body noise, and other data also need to be considered to make these data meet the national standard requirements. Finally, after multiple calculations and experiments, the optimal structure parameters are obtained, and the volume and weight of the transformer are reduced.

[0047] Specifically, as shown in Figure 3 and Figure 7As shown, the winding 1 includes a low-voltage winding 101 and a high-voltage winding 102, the low-voltage winding 101 is assembled on the iron core, and the high-voltage winding 102 is assembled on the low-voltage winding 101, lead wires 2 are arranged on the low-voltage winding 101 and the high-voltage winding 102, low-voltage oil channels are arranged between adjacent low-voltage windings 101, high-voltage oil channels are arranged between adjacent high-voltage windings 102, and high-low voltage oil channels are arranged between the low-voltage winding 101 and the high-voltage winding 102.

[0048] Insulating plates are arranged in the low-voltage oil channels, the high-voltage oil channels, and the high-low voltage oil channels between the windings 1, which play an insulating role and also play a supporting role.

[0049] Specifically, the outermost layer of the high-voltage winding 102 is bound with an epoxy paint glass fiber weftless binding tape.

[0050] Specifically, as shown in Figure 1 , the lead wire 2 adopts a three-dimensional lead wire structure.

[0051] The low-voltage lead wire is vertically arranged on the outside to form a triangular space, and the high-voltage tapping lead wire is vertically arranged inside the triangular space of the low-voltage lead wire, and the whole is a three-dimensional lead wire structure, occupying less space.

[0052] Specifically, as shown in Figure 4 and Figure 8 , an insulating paper board 303 is arranged between adjacent iron core columns 302, which plays an insulating role.

[0053] Specifically, as shown in Figure 4 and Figure 6 , the clamp group 4 is a triangular structure.

[0054] Specifically, as shown in Figures 4 to 6 , the pressing plate group 5 includes a winding pressing plate 501, an iron yoke pressing plate 502, and a center pressing plate 503, the winding pressing plate 501 is fixedly installed at three corners of the clamp group 4 respectively, the iron yoke pressing plate 502 is fixedly installed at three edges of the clamp group 4 respectively, the center pressing plate 503 is fixedly installed at the center of the inner wall of the clamp group 4, and the inner end of the iron yoke pressing plate 502 is attached to the side wall of the center pressing plate 503.

[0055] The winding pressing plate 501 is used to support and limit the winding 1, the iron yoke pressing plate 502 is used to support and limit the iron yoke frame 301 and part of the winding 1, and the center pressing plate 503 is used to support and limit part of the winding 1.

[0056] Specifically, as shown in Figures 4 to 6 , the surfaces of the winding pressing plate 501, the iron yoke pressing plate 502, and the center pressing plate 503 towards the winding 1 are all provided with flow guide grooves 504, which serve as oil channels, and insulating plates can also be arranged in these oil channels, playing an insulating and supporting role.

[0057] Specifically, as shown in Figure 4 and Figure 6 The iron yoke pressing plate 502 comprises an outer pressing plate and an inner pressing plate, and the outer pressing plate and the inner pressing plate form a T-shaped structure, the inner end of the inner pressing plate is attached to the side wall of the center pressing plate 503, the flow guide grooves 504 of the outer pressing plate and the inner pressing plate are staggered and not communicated with each other, and the flow guide grooves 504 of the inner pressing plate are communicated with the flow guide grooves 504 of the center pressing plate 503.

[0058] Due to the staggered arrangement of the flow guide grooves 504 on the iron yoke pressing plate 502, different thermal convection zones are formed inside the transformer, the circulation of the oil is enhanced, which is beneficial to further improve the heat dissipation efficiency of the transformer, so that the transformer can still achieve good heat dissipation in the case of reduced volume and more compact internal space, and the working performance of the transformer is improved.

[0059] Holes are formed on the winding pressing plate 501, the iron yoke pressing plate 502 and the center pressing plate 503, which facilitates position limiting and installation, and stepped grooves are formed in communication with the holes, and phase spacing plates can be arranged in the stepped grooves. Because of the arrangement of the stepped grooves, the length of the phase spacing plates can be increased, and the phase creepage distance can be increased.

[0060] Embodiment two

[0061] For the optimization design of the three-dimensional iron core 3, the following steps are included:

[0062] During the design of the three-dimensional iron core 3, the weight and volume are mainly calculated, wherein the volume calculation needs to consider the cross-sectional area, window height, window width, circle radius, straight line segment and other data, and also needs to consider the calculation of coil structure size, wire cross section, wire length, resistance, weight calculation and magnetic flux.

[0063] Firstly, the cross-sectional shape of the iron core is determined, and the shortcomings of the circular cross-sectional iron core and the regular hexagonal cross-sectional iron core are designed. After multiple adjustments, the shape of the circular arc pentagon is determined.

[0064] Then, the cross-sectional area of the iron core is calculated:

[0065] As shown in Figure 9 For the calculation of the cross-sectional area of the three-dimensional iron core 3, it is divided into five sectors, five rectangles and one pentagon, and the total area is calculated.

[0066] Considering the difficulty of processing, the radius of the five sectors is set to be equal in the design, that is, R, so that the five quadrilaterals in the formula are rectangles. Figure 9

[0067] ​Therefore, the included angle a is complementary to the included angle a, the included angle b is complementary to the included angle β, the included angle c is complementary to the included angle θ, and the width of the inner plane 3021 is set as L1, the width of the outer plane 3022 is set as L2, and the width of the end plane 3023 is set as L3.

[0068] Total area The calculation formula of the total area of the five rectangles is:

[0069] ;

[0070] The calculation formula of the total area of the five rectangles is:

[0071] ;

[0072] The calculation formula of the total area of the five rectangles is:

[0073] ;

[0074] The calculation formula of the total area of the five rectangles is:

[0075] .

[0076] After determining the cross-sectional shape and cross-sectional area of the solid iron core 3, the weight of the solid iron core 3 is calculated :

[0077] ;

[0078] After substituting the related formula, the calculation formula of the weight of the solid iron core 3 is:

[0079] ;

[0080] In the formula:

[0081] The total weight of the solid iron core 3 is kg;

[0082] The weight of a single iron core column is kg;

[0083] The weight of a single frame iron core inner yoke is kg;

[0084] The weight of a single frame iron core inner corner is kg;

[0085] The core window height is mm;

[0086] ​​​​ Center distance, unit: mm

[0087] Yoke cross-sectional area, unit: mm 2 ;

[0088] Silicon steel sheet density, unit: kg / cm 3 , cold-rolled silicon steel sheet 7.65x10 -3 kg / cm 3 .

[0089] While completing the design of the three-dimensional iron core 3, the calculation of the coil structure size, wire cross-section, wire length, resistance, weight, and magnetic flux is carried out.

[0090] In the above calculation process, no-load loss, no-load current, and body noise need to be calculated to ensure that they meet the national standard requirements.

[0091] Example Three

[0092] For the performance parameters of the assembled three-dimensional transformer in Example One and the transformer with a circular cross-section, see Table 1.

[0093] Table 1 Comparison of performance parameters of three-dimensional core transformer optimization design

[0094]

[0095] As can be seen from the above table, on the basis of meeting the national standard requirements (contents 1 to 9 in the table), the performance parameters of the traditional core with a circular cross-section and the core with a circular-arc pentagonal cross-section in Example One are compared, wherein the weight of the three-dimensional core 3 (i.e. the weight of the silicon steel sheet), the weight of the wire, and the weight of the transformer oil in Example One are all lower than those of the transformer with a circular cross-section, and the total weight is also lower. At the same time, according to the core parameters, the volume of the three-dimensional core 3 in Example One is smaller than that of the traditional core, which makes the overall structure of the transformer in Example One more compact, making the transformer easier to integrate into a new energy system, and improving the overall integration of the system.

[0096] The above content is only the preferred embodiment of the present application. For those skilled in the art, according to the idea of the present application, many changes can be made in the specific implementation manner and application range, as long as these changes do not deviate from the concept of the present application, and all belong to the protection scope of the present application.

Claims

1. A compact prefabricated three-dimensional transformer, characterized in that: It includes a winding (1), a lead wire (2), a three-dimensional iron core (3), a clamping assembly (4), and a pressure plate assembly (5). There are two sets of the clamping assembly (4) and the pressure plate assembly (5). The three-dimensional iron core (3) is assembled between the two sets of the clamping assembly (4). The pressure plate assembly (5) is assembled on the inner wall of the clamping assembly (4). The winding (1) is disposed on the three-dimensional iron core (3) and the winding (1) is located between the two sets of the pressure plate assembly (5). The lead wire (2) is disposed on the winding (1). The three-dimensional iron core (3) is composed of three single-frame iron cores. The single-frame iron core includes an iron yoke frame (301) and an iron core column (302). Adjacent iron core columns (302) are spliced ​​together to form an iron core. The cross-sectional shape of the iron core is a circular arc pentagon. The two iron core columns (302) of the single-frame iron core are symmetrically provided with an inner plane (3021) and an outer plane (3022). The two inner planes (3021) are parallel and the two outer planes (3022) are coplanar. The included angle α between the two inner planes (3021) of the iron core is 120° and the included angle β between the inner plane (3021) and the outer plane (3022) of the iron core is 90°. The pressure plate assembly (5) includes a winding pressure plate (501), a yoke pressure plate (502), and a center pressure plate (503). The winding pressure plate (501) is fixedly installed at the three corners of the clamping assembly (4). The yoke pressure plate (502) is fixedly installed at the three sides of the clamping assembly (4). The center pressure plate (503) is fixedly installed at the center of the inner wall of the clamping assembly (4), and the inner end of the yoke pressure plate (502) is in contact with the side wall of the center pressure plate (503). The winding pressure plate (501), the yoke pressure plate (502), and the center pressure plate (503) all have guide grooves (504) on their surfaces facing the winding (1). The iron yoke pressure plate (502) includes an outer pressure plate and an inner pressure plate, and the outer pressure plate and the inner pressure plate form a T-shaped structure. The inner end of the inner pressure plate is attached to the side wall of the central pressure plate (503). The guide grooves (504) of the outer pressure plate and the inner pressure plate are staggered and do not communicate with each other. The guide groove (504) of the inner pressure plate is connected to the guide groove (504) of the central pressure plate (503).

2. The compact prefabricated three-dimensional transformer according to claim 1, characterized in that: The winding (1) includes a low-voltage winding (101) and a high-voltage winding (102). The low-voltage winding (101) is mounted on the iron core, and the high-voltage winding (102) is mounted on the low-voltage winding (101). Both the low-voltage winding (101) and the high-voltage winding (102) are provided with lead wires (2). A low-pressure oil passage is provided between adjacent low-voltage windings (101), and a high-pressure oil passage is provided between adjacent high-voltage windings (102). A high-low pressure oil passage is provided between the low-voltage winding (101) and the high-voltage winding (102).

3. A compact prefabricated three-dimensional transformer according to claim 2, characterized in that: The outermost layer of the high-voltage winding (102) is bound with epoxy-coated glass fiber non-woven binding tape.

4. A compact prefabricated three-dimensional transformer according to claim 1, characterized in that: The lead wire (2) adopts a three-dimensional lead wire structure.

5. A compact prefabricated three-dimensional transformer according to claim 1, characterized in that: An insulating paperboard (303) is provided between adjacent iron core columns (302).

6. A compact prefabricated three-dimensional transformer according to claim 1, characterized in that: The clamp assembly (4) has a triangular structure.

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