A power saving device three-dimensional winding core assembly
The problems of uneven magnetic flux and overheating in the core assembly of the transformer were solved by using a three-dimensional wound core assembly and a high-efficiency cooling system, thus achieving high efficiency, energy saving and stable operation.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- ANHUI ZHONGHAO ENERGY TECH CO LTD
- Filing Date
- 2025-10-23
- Publication Date
- 2026-06-23
AI Technical Summary
The core components of existing transformers suffer from uneven magnetic flux distribution due to internal splicing joints, resulting in high-resistivity areas and magnetic flux density distortion, which increases energy loss, makes them prone to overheating, and leads to poor stability and reliability.
The three-dimensional wound core assembly is adopted. The core is made of silicon steel sheets continuously wound into a "品" shape structure. The magnetic circuit is symmetrical and the length is the shortest. Combined with the transformer oil cooling system inside the outer shell, including pump group and heat dissipation fins, it can achieve efficient cooling and uniform magnetic flux distribution.
It effectively reduces energy loss by 10-20%, improves the stability and reliability of the core assembly, avoids splice seams and magnetic flux density distortion, and enhances cooling efficiency.
Smart Images
Figure CN121260643B_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of transformer component technology, and in particular to a three-dimensional wound iron core assembly for an energy-saving device. Background Technology
[0002] The core assembly is the main magnetic circuit part of the transformer, and together with the coil wound on it, it forms a complete electromagnetic induction system to efficiently conduct magnetic flux. In addition, by utilizing the high magnetic permeability of the core assembly, the magnetic field can be concentrated and guided to reduce magnetic resistance and improve the working efficiency of the transformer.
[0003] In existing transformers, the core components are mostly made of laminated silicon steel sheets. However, due to the presence of overlapping seams inside, the magnetic flux distribution in the internal magnetic circuit of the core component is poor. The overlapping seams also cause a significant high-resistance region in the core component, and magnetic flux density distortion occurs at the overlapping seams. This increases the energy loss of the transformer during operation and makes it prone to overheating, resulting in poor stability and reliability.
[0004] Therefore, there is an urgent need for a core assembly for transformers to solve the defects of the existing core assemblies in actual operation. Summary of the Invention
[0005] This application proposes a three-dimensional wound iron core assembly for energy saving, which has the advantage of effectively avoiding the generation of splice seams inside the iron core assembly, resulting in poor magnetic flux distribution in its internal magnetic circuit, obvious high resistance areas, or magnetic flux density distortion. This solves the problem that existing iron core assemblies have splice seams inside, which cause poor magnetic flux distribution in various parts of the internal magnetic circuit, obvious high resistance areas, and magnetic flux density distortion at the splice seams, thereby increasing the energy loss of the transformer during operation and easily causing overheating.
[0006] To achieve the above object, the present application adopts the following technical solution: A three-dimensional wound core assembly of a power-saving device, comprising a core assembly and an installation housing. The core assembly includes a lower bracket fixedly installed at the bottom of the inner cavity of the installation housing by bolts. At the top of the lower bracket, three cores arranged in a "pin" shape structure are fixedly installed, so that the magnetic path lengths of the three cores are exactly equal and the sum of the magnetic path lengths is the shortest. At the same time, the magnetic paths of the three cores are completely symmetrical and the no-load currents are completely balanced. Moreover, for the "pin" shape structure arrangement of the three cores, the material consumption of the yoke part in the core can be effectively reduced. At the same time, the structural composition of the core assembly is greatly optimized, making its floor area smaller. At the top of the three cores, an upper bracket is provided to fix its top. At the same time, several groups of terminal blocks are provided on the side end face of the upper bracket, so that the core can be connected to an external current through the terminal blocks. At the same time, between the lower bracket and the upper bracket, three hollow-structured tie rods arranged in a circular array are provided;
[0007] The installation housing includes an outer housing fixedly installed with the lower bracket at the bottom of the inner cavity, and an end cover is provided at the top of the outer housing to enclose the core assembly therein. Transformer oil for submerging the core is filled in the inner cavity of the outer housing. Then, the core assembly can be insulated, cooled, and arc extinguished through the filled transformer oil.
[0008] Furthermore, the core is continuously and tightly wound from silicon steel strip materials without interruption, and its winding direction is the same as its magnetization direction. For the setting of the core, the problem of lap joints inside the core is effectively avoided, and there is no obvious high-resistance area or the phenomenon of magnetic flux density distortion at the lap joints;
[0009] Moreover, on the premise of the same material, compared with the laminated core assembly, the iron loss process coefficient of this wound core assembly drops from between 1.3 and 1.5 to about 1.05. Just this item can reduce the loss of the core assembly by 10-20%;
[0010] At the same time, the silicon steel sheets for making the core need to be annealed in vacuum with nitrogen filling at a high temperature (800 °C), thereby eliminating the mechanical stress inside the core and refining the magnetic domains of the silicon steel sheets, and improving its ability of secondary recrystallization.
[0011] Furthermore, the outer shell has three sets of internal chambers corresponding to the positions of three sets of iron cores, and three sets of pump groups corresponding to the positions of the internal chambers are located on the top of the outer surface of the outer shell. At the same time, a first connecting pipe is fixedly installed at the input end of the pump group, connecting to the bottom of the inner cavity of the inner chamber, and a second connecting pipe is fixedly installed at the output end of the pump group, connecting to the top of the pull rod. The pull rod has several sets of first through holes arranged in a linear array. Thus, when the temperature of the transformer fluid in the inner cavity of the outer shell is too high, under the action of the pump group, the transformer fluid with a lower temperature in the inner chamber can be squeezed and transported to the inner cavity of the outer shell through the pull rod, and a certain degree of disturbance is generated to the transformer fluid with a higher temperature, forming a convection effect to accelerate the heat exchange between them.
[0012] Furthermore, a flow hole is provided at the top of the inner cavity of the outer shell, which connects to the inner cavity of the inner cavity. The position of the flow hole is higher than the top of the iron core, so that the outer shell and the transformer fluid in the inner cavity can form a complete flow circuit with the pump assembly. This allows the transformer fluid with a higher temperature in the outer shell to flow back to the inner cavity for cooling through the flow hole.
[0013] Furthermore, a movable ring is provided on the outer surface of the pull rod at the corresponding position of the first through hole, and a second through hole corresponding to the first through hole is provided on the movable ring. Initially, the second through hole is located below the first through hole. The bottom end of the movable ring is provided with an expansion ring that is fixedly connected to the outer surface of the pull rod. When the temperature of the transformer fluid in the inner cavity of the outer shell reaches a certain value, the expansion ring will cause the movable ring to move upward due to thermal expansion, thereby making the first through hole and the second through hole interconnected.
[0014] Furthermore, the expansion ring is equipped with a thermistor inside and forms an electrical feedback connection with the pump assembly. Thus, when the temperature of the transformer oil in the inner cavity of the outer shell reaches a certain value, the pump assembly can be automatically triggered to squeeze and transport the lower temperature transformer oil in the inner cavity to the inner cavity of the outer shell while connecting the first through hole and the second through hole.
[0015] Furthermore, heat dissipation fins are provided on the outer surface of the outer casing and at the corresponding position in the inner cavity, thereby accelerating the cooling rate of the transformer fluid in the inner cavity.
[0016] The beneficial effects of this invention are as follows:
[0017] 1. A three-dimensional wound core assembly of a power-saving device provided by the present application effectively avoids the problem of lap joints inside the core through the arrangement of the core and its upper structure, thereby eliminating obvious high-resistance regions or the phenomenon of magnetic flux density distortion at the lap joints. The "pin" structure arrangement of the three cores makes the magnetic path lengths of the cores completely equal and the sum of the magnetic path lengths the shortest. At the same time, the magnetic paths between the three cores are completely symmetric and the no-load currents are completely balanced, effectively reducing the energy loss during operation.
[0018] 2. A three-dimensional wound core assembly of a power-saving device provided by the present application, through the arrangement of the outer casing and its upper structure, when the temperature of the transformer liquid in the inner cavity of the outer casing is too high, under the action of the pump group, the relatively cooler transformer liquid in the inner cavity can be squeezed and transported through the pull rod into the inner cavity of the outer casing, disturbing the relatively hotter transformer liquid to a certain extent, forming a convection effect to accelerate the heat exchange between them, thereby improving the cooling rate of the core assembly and effectively enhancing the stability and reliability of the core assembly during operation. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings described below are only the embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on the provided drawings:
[0020] Figure 1 It is a schematic structural diagram of the core assembly of the present invention;
[0021] Figure 2 It is a front view of the core assembly of the present invention;
[0022] Figure 3 It is a top view of the core assembly of the present invention;
[0023] Figure 4 It is a schematic installation structure diagram of the core assembly of the present invention;
[0024] Figure 5 It is the structure of the present invention Figure 4 front view;
[0025] Figure 6 It is a schematic structure diagram of the installation housing of the present invention;
[0026] Figure 7 It is the structure of the present invention Figure 1 enlarged schematic view of part A in the structure.
[0027] In the figure: 1 - lower bracket, 2 - upper bracket, 3 - iron core, 4 - terminal, 5 - tie rod, 6 - outer shell, 7 - inner cavity, 8 - end cover, 9 - pump pressure group, 10 - first connecting pipe, 11 - second connecting pipe, 12 - flow hole, 13 - movable ring, 14 - expansion ring. Detailed implementation manners
[0028] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.
[0029] As Figure 1 、 Figure 4 shown, a three-dimensional wound core assembly of a power-saving device includes a core assembly and an installation shell. The core assembly includes a lower bracket 1 fixedly installed at the bottom of the inner cavity of the installation shell by bolts. As Figure 2 、 Figure 3 shown, three groups of cores 3 arranged in a "pin" shape structure are fixedly installed at the top of the lower bracket 1, so that the magnetic path lengths of the three groups of cores 3 are completely equal and the sum of the magnetic path lengths is the shortest. At the same time, the magnetic paths of the three groups of cores 3 are completely symmetrical, and the no-load currents are completely balanced. Moreover, for the arrangement of the three groups of cores 3 in a "pin" shape structure, the material consumption of the yoke part in the core 3 can be effectively reduced. At the same time, the structural composition of the core assembly is greatly optimized, making its floor area smaller. And at the top of the three groups of cores 3, there is an upper bracket 2 to fix its top. At the same time, several groups of terminals 4 are provided on the side end face of the upper bracket 2, so that the core 3 can be connected to an external current through the terminals 4. At the same time, between the lower bracket 1 and the upper bracket 2, there are three tie rods 5 arranged in a circular array and having a hollow structure inside;
[0030] As Figure 5 、 Figure 6 shown, the installation shell includes an outer shell 6 fixedly installed with the lower bracket 1 at the bottom of the inner cavity, and an end cover 8 is provided at the top of the outer shell 6 to wrap the core assembly therein. And transformer oil submerging the core 3 is filled in the inner cavity of the outer shell 6. Thus, the core assembly can be insulated, cooled and arc extinguished through the filled transformer oil.
[0031] In this technical solution, the core 3 is continuously and tightly wound by silicon steel strip materials without interruption, and its winding direction is the same as its magnetization direction. Among them, for the setting of the core 3, the problem of generating lap joints inside the core 3 is effectively avoided, and there is no obvious high-resistance area or the phenomenon of magnetic flux density distortion at the lap joints;
[0032] Furthermore, under the premise of the same material, the iron loss process coefficient of the wound iron core assembly is reduced from 1.3-1.5 to about 1.05 compared with the laminated iron core assembly. This alone can reduce the loss of the iron core assembly by 10-20%.
[0033] Meanwhile, the silicon steel sheet used to make the core 3 needs to undergo high-temperature (800℃) vacuum nitrogen annealing treatment, which eliminates the mechanical stress inside the core 3, refines the magnetic domains of the silicon steel sheet, and improves its ability to recrystallize.
[0034] like Figure 5 , Figure 6 As shown, in this technical solution, the interior of the outer casing 6 has three sets of inner chambers 7 corresponding to the positions of the three sets of iron cores 3, and three sets of pump groups 9 corresponding to the positions of the inner chambers 7 are provided on the top of the outer surface of the outer casing 6. At the same time, a first connecting pipe 10 is fixedly installed at the input end of the pump group 9, connecting to the bottom of the inner chamber 7, and a second connecting pipe 11 is fixedly installed at the output end of the pump group 9, connecting to the top of the pull rod 5. The pull rod 5 has several sets of first through holes arranged in a linear array. When the temperature of the transformer fluid in the inner cavity of the outer casing 6 is too high, under the action of the pump group 9, the transformer fluid with a lower temperature in the inner chamber 7 can be squeezed and transported to the inner cavity of the outer casing 6 through the pull rod 5, and a certain degree of disturbance is generated to the transformer fluid with a higher temperature, forming a convection effect to accelerate the heat exchange between them.
[0035] like Figure 6 As shown, in this technical solution, a flow hole 12 is provided at the top of the inner cavity of the outer shell 6, which connects to the inner cavity of the inner chamber 7. The position of the flow hole 12 is higher than the top of the iron core 3, so that the outer shell 6 and the transformer fluid in the inner chamber 7 can form a complete flow circuit with the pump assembly 9. The transformer fluid with a higher temperature in the outer shell 6 can flow back to the inner chamber 7 through the flow hole 12 for cooling.
[0036] like Figure 7 As shown, in this technical solution, a movable ring 13 is provided on the outer surface of the pull rod 5 at the corresponding position of the first through hole, and a second through hole corresponding to the first through hole is provided on the movable ring 13. Initially, the second through hole is located below the first through hole. An expansion ring 14 is provided at the bottom end of the movable ring 13 and is fixedly connected to the outer surface of the pull rod 5. When the temperature of the transformer fluid in the inner cavity of the outer shell 6 reaches a certain value, the expansion ring 14 causes the movable ring 13 to move upward due to thermal expansion, so that the first through hole and the second through hole are connected to each other.
[0037] In this technical solution, the expansion ring 14 is equipped with a thermistor and forms an electrical feedback connection with the pump assembly 9. Thus, when the temperature of the transformer oil in the inner cavity of the outer casing 6 reaches a certain value, the pump assembly 9 can be automatically triggered to squeeze and transport the lower temperature transformer oil in the inner chamber 7 into the inner cavity of the outer casing 6 while connecting the first through hole and the second through hole.
[0038] like Figure 4 As shown, in this technical solution, heat dissipation fins are provided on the outer surface of the outer shell 6 and at the corresponding position in the inner cavity 7, thereby accelerating the cooling rate of the transformer fluid in the inner cavity 7.
[0039] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. A three-dimensional wound core assembly of a power-saving device, comprising a core assembly and a mounting housing, characterized in that: The core assembly includes a lower bracket (1) fixedly installed at the bottom of the inner cavity of the mounting housing. At the top of the lower bracket (1), three cores (3) arranged in a "pin" shape structure are fixedly installed, and an upper bracket (2) is provided at the top of the three cores (3) to fix their tops. A number of wiring terminals (4) are provided on the side end face of the upper bracket (2). A hollow-structured pull rod (5) is provided between the lower bracket (1) and the upper bracket (2); A number of first through holes arranged in a linear array are formed on the pull rod (5). An activity ring (13) is provided on the outer surface of the pull rod (5) at the corresponding positions of the first through holes thereon. A second through hole corresponding to the first through hole is formed on the activity ring (13). Initially, the second through hole is located below the first through hole. The bottom end of the activity ring (13) is provided with an expansion ring (14) whose bottom is fixedly connected to the outer surface of the pull rod (5). A thermistor is provided inside the expansion ring (14), and an electrical feedback connection is formed with a pump pressure group (9); The mounting housing includes a housing body (6) fixedly installed with the lower bracket (1) at the bottom of the inner cavity. An end cover (8) is provided at the top of the housing body (6) to wrap the core assembly therein. Transformer oil submerging the cores (3) is filled in the inner cavity of the housing body (6); Three inner cavities (7) corresponding to the positions of the three cores (3) are provided inside the housing body (6). Three pump pressure groups (9) corresponding to the positions of the inner cavities (7) are provided on the top of the outer surface of the housing body (6). A first connecting pipe (10) is fixedly installed at the input end of the pump pressure group (9) and is connected to the bottom of the inner cavity (7). A second connecting pipe (11) is fixedly installed at the output end of the pump pressure group (9) and is connected to the top end of the pull rod (5). A circulation hole (12) communicating to the inner cavity (7) is formed at the top of the inner cavity of the housing body (6). The position height of the circulation hole (12) is higher than the top of the core (3). Thus, the transformer liquid in the inner cavity of the housing body (6) and the inner cavity (7) cooperates with the pump pressure group (9) to form a complete circulation loop, and the transformer liquid with a higher temperature in the inner cavity of the housing body (6) flows back to the inner cavity (7) through the circulation hole (12) for cooling treatment.
2. The three-dimensional wound iron core assembly of the energy-saving device according to claim 1, characterized in that, The core (3) is continuously wound from a silicon steel strip, and its winding direction is the same as its magnetization direction.
3. The three-dimensional wound iron core assembly of the energy-saving device according to claim 1, characterized in that, Heat dissipation fins are provided on the outer surface of the housing body (6) at the corresponding positions of the inner cavities (7).