Core stack structure for reducing transformer losses
By designing a "日"-shaped iron core structure and a fully oblique joint connection, and adjusting the thickness and width of the silicon steel sheet assembly, the high loss and noise problems of the transformer iron core were solved, resulting in a reduction in loss and noise as well as a reduction in material costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- XIN YU ELECTRIC TECH CO LTD
- Filing Date
- 2025-07-15
- Publication Date
- 2026-07-24
AI Technical Summary
The core structure design of existing transformers results in high hysteresis losses and noise, making it difficult to effectively reduce losses and material costs.
The iron core structure is spliced into the shape of the Chinese character "日" (sun). The silicon steel sheet components are stacked in a stepped manner, with the middle being wider and the outer side narrower. Combined with the full oblique joint connection, the thickness and width of the silicon steel sheet components are adjusted to control the magnetic flux density below the saturation point and reduce the use of edge materials.
It significantly reduces core loss and noise, with hysteresis loss decreasing by 10%, noise decreasing by 2-4 dB, and material costs decreasing.
Smart Images
Figure CN224554132U_ABST
Abstract
Description
Technical Field ,
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[0001] The utility model belongs to the field of transformers, and particularly relates to a core stacking structure for reducing transformer losses. Background Art
[0002] The core is the main magnetic circuit part in a transformer, and is usually stacked by hot-rolled or cold-rolled silicon steel sheets with a relatively high silicon content and an insulating paint coated on the surface. The core and the coil wound thereon form a complete electromagnetic induction system. The size of the power transmitted by the transformer depends on the material and cross-sectional area of the core. Reasonably setting the core structure can reduce the air gap and magnetic resistance in the magnetic circuit, and reduce the noise generated by the vibration of the core. <000(006>Content of the Utility Model
[0003] The purpose of the utility model is to provide a core stacking structure for reducing transformer losses by reasonably setting the core specifications.
[0004] To achieve the above purpose, the utility model provides a core stacking structure for reducing transformer losses, including a core spliced into a "day" shape. The core includes several silicon steel sheet assemblies stacked in a stepped manner. The width of the silicon steel sheet assembly in the middle is the largest, and the width of the silicon steel sheet assemblies on the outer side gradually decreases. The width and thickness of the silicon steel sheet assembly in the middle are 250 mm and 146 mm respectively. Starting from the silicon steel sheet assembly in the middle, nine groups of silicon steel sheet assemblies are arranged on both the front and back sides of the core. From the middle to the outside, the widths of the nine groups of silicon steel sheet assemblies are 245 mm, 235 mm, 225 mm, 215 mm, 200 mm, 180 mm, 160 mm, 140 mm, and 120 mm in sequence, and the thicknesses of the nine groups of silicon steel sheet assemblies are 25 mm, 18 mm, 11 mm, 10 mm, 11 mm, 12 mm, 9 mm, 8 mm, and 6 mm in sequence.
[0005] As an improvement of the above solution, clamping plates for adding several silicon steel sheet assemblies are arranged on the outermost front and back sides of the core.
[0006] As an improvement of the above solution, each group of silicon steel sheet assemblies includes several silicon steel sheets with the same size and stacked on top of each other.
[0007] As an improvement of the above solution, the core adopts a full-bevel joint connection method. The core includes yoke sheets on the upper and lower sides, side columns on the left and right sides, and a middle column in the middle. The end faces of the side columns are set at a 45° bevel, the head and tail ends of the middle column are set at 90° right angles, the head and tail ends of the yoke sheets are set at 45° bevels, and a 90° right-angle notch is arranged in the middle of the yoke sheets.
[0008] As an improvement of the above solution, the maximum left-right length of the core is 1390 mm, and the maximum up-down height is 1175 mm.
[0009] This invention offers the following advantages: the stepped stacked structure, wider in the middle and narrower on the outside, controls the magnetic flux density below the saturation point by matching the magnetic flux density distribution, thereby reducing hysteresis loss and minimizing unusable edge material, significantly lowering core loss and material costs. Compared to the results of the "empirical formula for calculating width gradient," the proposed dimensional design slightly adjusts the thickness of different groups of silicon steel sheet assemblies, resulting in a 2-4 dB reduction in noise and a 10% decrease in hysteresis loss. Attached Figure Description
[0010] Figure 1 A front view of the core structure in one embodiment;
[0011] Figure 2 This is a schematic diagram of a cross-sectional view of the iron core in one embodiment;
[0012] Figure 3 This is a top view of an embodiment after the iron core has been installed;
[0013] Figure 4 This is a front view of the iron core after it has been installed in one embodiment.
[0014] Explanation of reference numerals in the attached drawings: 10, side column; 20, center column; 30, yoke; 40, silicon steel sheet assembly. Detailed Implementation
[0015] In the description of this utility model, it should be noted that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "top surface", "bottom surface", "inner", "outer", "inner side", "outer side", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.
[0016] In the description of this invention, "several" means one or more, "multiple" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. Where the terms "first," "second," and "third" are used for descriptive purposes and to distinguish technical features, they should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the sequential relationship of the indicated technical features.
[0017] In the description of the present utility model, it should be noted that unless otherwise clearly specified and defined, the terms "installation", "connection", "linkage", and "setting" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present utility model can be understood according to specific circumstances. The embodiments of the present utility model will be described below according to its overall structure.
[0018] Referring to Figures 1 to 4 , the present utility model discloses a core stacking structure for reducing transformer losses, including a core spliced into a "day" shape. The core includes a number of silicon steel sheet assemblies 40 stacked in a stepped manner. The width of the silicon steel sheet assembly 40 in the middle is the largest, and the width of the silicon steel sheet assemblies 40 on the outside gradually decreases. The width and thickness of the middle silicon steel sheet assembly 40 are 250 mm and 146 mm respectively. Starting from the middle silicon steel sheet assembly 40, nine groups of silicon steel sheet assemblies 40 are provided on both the front and back sides of the core. From the middle to the outside, the widths of the nine groups of silicon steel sheet assemblies 40 are 245 mm, 235 mm, 225 mm, 215 mm, 200 mm, 180 mm, 160 mm, 140 mm, and 120 mm in sequence, and the thicknesses of the nine groups of silicon steel sheet assemblies 40 are 25 mm, 18 mm, 11 mm, 10 mm, 11 mm, 12 mm, 9 mm, 8 mm, and 6 mm in sequence.
[0019] As an improvement to the above solution, clamping plates for adding a number of silicon steel sheet assemblies 40 are provided on the front and back sides of the outermost part of the core. As shown in Figure 2 , the clamping plates are respectively located at the uppermost and lowermost positions.
[0020] As an improvement to the above solution, each group of silicon steel sheet assemblies 40 includes a number of silicon steel sheets of the same size and stacked on top of each other. Further, the thickness of each silicon steel sheet is 0.35 mm - 0.65 mm, and an insulating coating is applied to the silicon steel sheets.
[0021] As an improvement to the above solution, the core adopts a full oblique joint connection method. The core includes yoke sheets 30 on both the upper and lower sides, side columns 10 on both the left and right sides, and a middle column 20 in the middle. The end faces of the side columns 10 are set at a 45° oblique angle, the head and tail ends of the middle column 2 are set at a 90° right angle, the head and tail ends of the yoke sheets 30 are set at a 45° oblique angle, and a 90° right-angle notch is provided in the middle of the yoke sheets 30.
[0022] As an improvement to the above solution, the maximum length of the core from left to right is 1390 mm, and the maximum height from top to bottom is 1175 mm.
[0023] The stepped stacked structure, wider in the middle and narrower on the outside, controls the magnetic flux density below the saturation point by matching the magnetic flux density distribution. This reduces hysteresis loss and unusable edge material, significantly lowering core loss and material costs. Compared to the results of the "empirical formula for calculating width gradient," the proposed size design slightly adjusts the thickness of different groups of silicon steel sheet assemblies 40, resulting in a 2-4 dB reduction in noise and a 10% decrease in hysteresis loss.
[0024] The foregoing description of specific exemplary embodiments of the present invention is for illustrative and explanatory purposes. These descriptions are not intended to limit the present invention to the precise forms disclosed, and it will be apparent that many changes and variations can be made in accordance with the foregoing teachings. The exemplary embodiments were chosen and described in order to explain the specific principles of the present invention and its practical application, thereby enabling those skilled in the art to implement and utilize various different exemplary embodiments of the present invention, as well as various different choices and variations. The scope of the present invention is intended to be defined by the claims and their equivalents.
Claims
1. A core stacking structure for reducing transformer losses, including a core spliced into a "day" shape, characterized in that: The iron core comprises several silicon steel sheet assemblies stacked in a stepped manner. The silicon steel sheet assembly in the middle has the largest width, and the width of the silicon steel sheet assemblies on the outer side gradually decreases. The width and thickness of the middle silicon steel sheet assembly are 250mm and 146mm, respectively. Starting from the middle silicon steel sheet assembly, nine sets of silicon steel sheet assemblies are arranged on both the front and rear sides of the iron core. From the middle to the outer side, the widths of the nine sets of silicon steel sheet assemblies are 245mm, 235mm, 225mm, 215mm, 200mm, 180mm, 160mm, 140mm, and 120mm, respectively, and the thicknesses of the nine sets of silicon steel sheet assemblies are 25mm, 18mm, 11mm, 10mm, 11mm, 12mm, 9mm, 8mm, and 6mm, respectively.
2. The core stacking structure according to claim 1, characterized in that: The outermost front and rear sides of the iron core are provided with clamps for adding several silicon steel sheet assemblies.
3. The core stacking structure according to claim 2, characterized in that: Each silicon steel sheet assembly consists of several silicon steel sheets of the same size, stacked on top of each other.
4. The iron core stacking structure according to claim 1, characterized in that: The iron core adopts a fully oblique joint connection method. The iron core includes yoke plates on the upper and lower sides, side posts on the left and right sides, and a central post in the middle. The end face of the side post is set at a 45° oblique angle, the beginning and end of the central post are set at a 90° right angle, the beginning and end of the yoke plate are set at a 45° oblique angle, and a 90° right angle notch is set in the middle of the yoke plate.
5. The core stacking structure according to claim 4, characterized in that: The maximum horizontal length of the iron core is 1390mm, and the maximum vertical height is 1175mm.