Amorphous transformer

Abstract

To improve an insulation material interposed between wound cores to be made to self-stand in an amorphous transformer for making the wound cores self-stand and fixing the wound cores.SOLUTION: Non-magnetic insulation materials are interposed between facing surfaces of wound cores 21 to 24 arranged in parallel in a lamination direction and a parallel direction. The insulation materials are formed respectively so as to be separated into an upper side insulation material 30 and a lower side insulation material 40 and an upper side insulation material 60 and a lower side insulation material 70 that have different heatproof temperatures, and the insulation materials are formed in a T shape or a cross shape using an FRP flat plate. The upper side insulation materials 30, 60 which are easily to be at high temperatures are manufactured using materials having heat resistance higher than that of the lower side insulation materials 40, 60. The lower side insulation materials 40, 70 are fixed to steel material bases 50, 80 on which the wound cores 21 to 24 are mounted, so that the wound cores 21 to 24 are preferably supported.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a technology for providing an amorphous transformer, and particularly relates to an improvement of a support member when assembling an amorphous core independently.

Background Art

[0002] In recent years, transformers using non-crystalline magnetic alloys and amorphous materials have been developed. When an amorphous material is adopted for a transformer core, support members are required for each core in order to assemble the core independently. As such a support member, Patent Document 1 discloses that, in order to improve the sagging of the corner portions of each core when standing independently and to smoothly assemble the core and the coil, a corner portion support member and a plate-shaped core support member fixed to the corner portion support member are used.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Patent Document 1 does not disclose the material of the core support member. According to the study by the inventors, it has been found that the following problems exist in the selection of the material of the support member for standing an amorphous core independently. The core support member requires strength to stand the core independently, and the adoption of steel material is conceivable. However, if a steel material (magnetic material) is adopted for the core support member, eddy currents are generated by the magnetic flux generated in the coil, causing local heating, generating combustible gas, and possibly causing abnormalities in the transformer. In addition, as a material to be adopted for the core support member, a resin material is conceivable, but a resin material with high heat resistance has lower strength than steel material, and there is a possibility that the transformer as a whole becomes larger and the cost increases.

[0005] In recent years, while transformers are being made larger in capacity, it is also important to make them compact while avoiding increasing their size due to installation space constraints. When the volume of the iron core increases, the weight of the iron core itself increases, and the coil dimensions and weight also increase. Therefore, it is expected that the assembly work of inserting the coil into the iron core will become difficult. In addition, during and after the assembly work, it is necessary to devise a way to keep the iron core standing upright well.

[0006] The present invention has been made in view of the above background, and an object of the present invention is to realize an amorphous transformer capable of properly holding a plurality of iron cores at appropriate intervals in a self-standing state. Another object of the present invention is to realize an amorphous transformer that can smoothly assemble the iron core and the coil by forming an insulating plate interposed between a plurality of iron cores by dividing it vertically. Still another object of the present invention is to realize an amorphous transformer in which the insulating plate on the side where the temperature is likely to rise among the vertically divided insulating plates is made of a material with a higher heat-resistant temperature.

Means for Solving the Problems

[0007] The present invention has been made to achieve the above object, and typical features are as follows. According to one feature of the present invention, there is provided an amorphous transformer including a plurality of amorphous wound cores arranged side by side in the stacking direction and the parallel direction, a support member for making the wound cores self-supporting, a coil formed by winding around a leg of any one of the plurality of wound cores, and an upper clamping metal fitting and a lower clamping metal fitting for fixing the wound cores. An insulating material is provided to keep a certain interval between end faces of legs of wound cores adjacent in the stacking direction and to keep a certain interval between side faces of legs of wound cores adjacent in the parallel direction. This insulating material is formed by dividing it into a lower insulating material fixed to the support member and an upper insulating material having a different heat-resistant temperature from the lower insulating material. The insulating material is made of resin or resin containing reinforcing fibers, and is formed such that the heat-resistant temperature of the upper insulating material is higher than that of the lower insulating material. The upper insulating material is fixed by the upper clamping metal fitting so as to be sandwiched between two wound cores at a position spaced apart from the lower insulating material by a gap.

[0008] According to another feature of the present invention, the upper insulating material and the lower insulating material are flat plates made of FRP (Fiber Reinforced Plastics). The upper insulating material and the lower insulating material in contact with the magnetic leg passing through the coil are in a cross shape, and the upper insulating material and the lower insulating material in contact with the magnetic leg not passing through the coil are in a T shape. It is preferable that the upper end positions of the cross-shaped lower insulating material and the T-shaped lower insulating material are each located above the center of gravity position in the vertical direction of the wound core. For the cross-shaped upper insulating material and the cross-shaped lower insulating material, two rectangular plates formed with a slit extending longitudinally from the center position of one short side of the rectangular plate in the longitudinal direction are prepared, and they are assembled in a crossed state so that the slits of the two rectangular plates are fitted to form a cross shape. On the other hand, the T-shaped upper insulating material and the cross-shaped lower insulating material are assembled by bonding two plates with adhesive or fitting them with slits.

Advantages of the Invention

[0009] According to the present invention, it becomes possible to make the amorphous wound core self-standing, and by using the upper insulating material and the lower insulating material in combination, a plurality of wound cores can be held at a predetermined interval in a self-standing state. Further, with the lower portion of the wound core and the lower insulating material fixed to the support member, the coil can be inserted and the joint of the lap portion of the wound core can be performed, so that the assembly work of inserting the coil into the core becomes easy. Furthermore, by using a heat-resistant material for the insulating plate, the restriction on the temperature rise of the transformer cooling medium (oil) is reduced, and even in a large-capacity transformer, it is possible to achieve compactification by reducing the cooler. In particular, by forming the insulating plate by dividing it vertically and horizontally, a material having properties suitable for the temperature distribution during transformer operation can be adopted, and the manufacturing cost can be suppressed. As a result, even when the transformer is increased in capacity, it is possible to maintain the characteristics of the transformer well.

Brief Description of Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Modes for Carrying Out the Invention

[0011] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following figures, the same parts are denoted by the same reference numerals, and repeated explanations will be omitted. In this specification, the directions of front, rear, left, right, up, and down are described as the directions shown in the figures. Also, in the alignment of the wound cores 21 to 24, the stacking direction and the parallel direction are described as the directions shown in the figures.

Embodiment

[0012] FIG. 1 is a perspective view showing the whole of an amorphous transformer 1 according to an embodiment of the present invention. The amorphous transformer 1 shown in FIG. 1 is of a single-phase outer-iron type and is mainly composed of a coil 10 and an amorphous core 2 (such as wound cores 21 and 23). Hereinafter, in this specification, when referring to the whole of a plurality of wound cores 21 to 24, it will simply be referred to as "core 2", and when referring to individual parts of the core 2, they will be divided by reference numerals such as 21 to 24 and shown as "wound cores 21 to 24". The wound cores 21 to 24 (reference numerals 22 and 23 refer to FIG. 2 described later) are formed in an annular shape and are made of a non-crystalline magnetic alloy, for example, an amorphous metal mainly composed of iron. The atomic arrangement inside the amorphous metal is different from that of ordinary metals. When a heated metal cools, it forms crystals. However, if it is cooled rapidly enough so that there is no time for crystals to form, it becomes an amorphous metal having no crystal structure. The wound cores 21 to 24 (22 and 24 refer to FIG. 2 described later) form a closed magnetic circuit and are manufactured using a known amorphous core manufacturing process. Insulating materials 30, 40 (see FIG. 2), 60, and 70 are interposed between the cores 2 adjacent in the stacking direction, and the wound cores 22 to 24 constituting the core 2 are maintained in a state having a slight gap.

[0013] The coil 10 is arranged so as to surround the adjacent magnetic leg portions of the core 2 as shown in FIG. 1. The core 2 is positioned on a steel support member (such as a steel base 80) with two wound cores arranged in the stacking direction and two in the parallel direction, and the upper and lower portions of the core 2 are fixed by an upper clamping metal fitting 15 and a lower clamping metal fitting 16.

[0014] FIG. 2 is a cross-sectional perspective view of the vicinity of the core 2 and the coil 11 of the amorphous transformer 1. FIG. 2 is a view in which the upper clamping metal fitting 15, the lower clamping metal fitting 16, and the wound core 23 are removed from the state of FIG. 1, and further, a part is shown in cross section. The shape of the wound core 23 (see FIG. 1) not shown is the same as those of the other wound cores 21, 22, 24, and these can be formed as common parts. Incidentally, the wound cores 21 to 24 are formed in a split form for insertion of the coil, and after the coil 10 is inserted into the magnetic leg portions of the wound cores 21 to 24, the removed portions (lap portions) of the split wound cores 21 to 24 are joined to each other, but the joining locations and the joining structure are not shown in FIG. 2.

[0015] The core 2 arranges two wound cores 21 and 22 in the stacking direction (front-rear direction in FIG. 1), and arranges the wound cores 23 and 24 so as to be adjacent in the parallel direction (left-right direction in FIG. 2) to those wound cores 21 and 22. The coil 10 is arranged so as to wind around one magnetic leg portion of the four wound cores 21 to 24. The rear end face of the wound core 21 and the front end face of the wound core 22 are arranged to face each other with a slight distance therebetween, and the rear end face of the wound core 23 (not shown) and the front end face of the wound core 24 are arranged to face each other with a slight distance therebetween. Insulating members (upper insulating material 30 and lower insulating material 40) made of a non-magnetic material are interposed between the wound cores 21 to 24 arranged with this distance therebetween. Also, insulating members (upper insulating material 60 and lower insulating material 70) are provided in the gap portions of the magnetic leg portions (portions extending in the vertical direction of the wound core) extending in the vertical direction on the side where the coil 10 is not wound, among the wound cores 21 and 22. Similarly, insulating members (upper insulating material 60 and lower insulating material 70) are provided in the gap portions of the magnetic leg portions extending in the vertical direction on the side where the coil 10 is not wound, among the wound cores 23 and 24 whose illustration is omitted. The upper insulating material 30 and the lower insulating material 40 are in a non-contact state and are arranged with a distance S therebetween in the vertical direction. Similarly, the upper insulating material 60 and the lower insulating material 70 are in a non-contact state and are arranged with a distance S therebetween in the vertical direction.

[0016] At the lower corner portions of the wound cores 21 to 24, one steel base 50 and two steel bases 80 are provided to make the wound cores 21 to 24 stand independently in the vertical direction. In this specification, when the steel bases 50 and 80 of the amorphous transformer 1 are placed on the floor surface or the like, the side where the steel bases 50 and 80 are located is called the lower side, and the side far from the steel bases 50 and 80 is called the upper side. The steel bases 50 and 80 are formed by a plurality of plates (described later with reference to FIGS. 3A and 3B) having a contour along the shape of the arc-shaped corner portions on the lower side of the wound cores 21 to 24.

[0017] The coil 10 is formed so as to surround the right magnetic leg portions extending in the vertical direction of the wound cores 21 and 22 and the left magnetic leg portions extending in the vertical direction of the wound cores 23 and 24. The coil 10 in FIG. 2 is formed by winding an enameled wire, and only the outer contour is schematically shown. The coil 10 includes a primary coil and a secondary coil, and the specific winding method and arrangement are not shown. The winding method of the coil 10 may adopt a known method, and any of the methods such as multilayer winding, split winding, bifilar winding, and sandwich winding can be adopted.

[0018] The side surfaces of the magnetic leg portions of the wound cores 21 and 22 where the coil 10 is not wound and the side surfaces of the magnetic leg portions of the wound cores 23 and 24 where the coil 10 is not wound are covered with side plates (insulating plates 66 and 76). Here, the insulating plates 66 and 76 are made of the same insulating material (insulating plates 61 and 71 described later with reference to FIG. 3B) as the other parts of the upper insulating material 60 and the lower insulating material 70 for ease of manufacture, and are formed in a T shape in a top view. The lower insulating material 70 is fitted into the slit portion of the steel base 80 and fixed using fixing means (for example, bolts and nuts). The upper insulating material 60 and the lower insulating material 70 are located above the lower insulating material 70 in a non-contact state with a predetermined gap 69 therebetween as shown by the arrow. The insulating materials 30 and 40 are cross-shaped in a top view, and each is arranged in a range that partially overlaps in the vertical direction within the internal space of the coil 10. On the other hand, the insulating materials 60 and 70 are arranged outside the coil 10.

[0019] The lower insulating material 40 is located at the center of the four wound iron cores 21 to 24 and is in contact with each of the wound iron cores 21 to 24. In order for the lower insulating material 40 to function to hold the wound iron cores 21 to 24 independently, it is formed to have a size such that the upper end of the lower insulating material 40 is located at a position higher than the individual center-of-gravity positions of the wound iron cores 21 to 24 and the center-of-gravity position of the entire iron core. In the example of FIG. 1, assuming the height of the upper ends of the wound iron cores 21 to 24 is H, the height H1 of the upper end of the lower insulating material 40 (see the reference numeral in FIG. 3A) is configured to satisfy the relationship H > H1 > H / 2. Further, if this height H1 is made lower than the height H2 of the upper end position of the coil 10, a sufficient height direction of the upper insulating material 30 can be ensured.

[0020] The upper insulating material 30 is disposed above the lower insulating material 40. A predetermined gap S is formed between the upper insulating material 30 and the lower insulating material 40. The shapes of the upper insulating material 30 and the lower insulating material 40 in a top view are the same, and they are fixed so as to be sandwiched in the gaps between the four adjacent wound iron cores 21 to 24. The upper insulating material 30 is configured to stably hold the wound iron cores 21 and 22 while maintaining a predetermined gap, stably hold the wound iron cores 23 (see FIG. 1) and 24 while maintaining a predetermined gap, and further stably hold the wound iron cores 21 and 23, and the wound iron cores 22 and 24 while maintaining a predetermined gap, and thus also functions as a spacer.

[0021] Among the magnetic leg portions of the wound cores 21 to 24, the upper insulating material 60 and the lower insulating material 70 are disposed on the side surfaces (the vertical portions of the outer peripheral surfaces) of the magnetic leg portions on the side where the coil is not wound. The upper insulating material 60 and the lower insulating material 70 provided so as to be in contact with the end surfaces in the stacking direction and the side surfaces in the parallel direction of the wound cores 21 and 22 are the same shape as the upper insulating material 60 and the lower insulating material 70 provided so as to be in contact with the end surfaces in the stacking direction and the side surfaces in the parallel direction of the wound cores 23 and 24, and common parts are used. Note that a part indicated by a dotted line of the upper insulating material 60 in contact with the wound cores 23 and 24 is not shown in the figure, and for the shape thereof, refer to FIG. 3 described later. The steel bases 50 and 80 hold the wound cores 21 to 24 in a self-supporting state, and the outer peripheral surfaces of the wound cores 21 to 24 are along a plurality of plates processed into curved surfaces, thereby preventing sagging due to the self-weight of the corner portions of the outer peripheral surface. Further, by manufacturing with a plurality of plates instead of a solid structure, the manufacturing costs of the steel bases 50 and 80 can be reduced compared with the conventional case. Furthermore, the steel bases 50 and 80 also function as bases for supporting the self-support of the lower insulating materials 40 and 70.

[0022] FIG. 3A is a perspective view of the insulating materials 30 and 40 arranged so as to penetrate the coil 10, the wound cores 21 to 24, and the steel base 50 that supports the insulating material 40. The insulating member arranged so as to penetrate the coil 10 is formed in a state of being divided into an upper insulating material 30 and a lower insulating material 40. The upper insulating material 30 is formed by combining two flat insulating plates 31 and 36, and these are arranged so as to cross in a cross shape. Similarly, the lower insulating material 40 is manufactured by combining two insulating plates 41 and 46, and these are arranged so as to cross in a cross shape. The insulating plate 31 (31a, 31b) and the insulating plate 41 are disposed between the end surfaces of adjacent cores, that is, between the wound cores 21 and 22, and between the wound cores 23 and 24.

[0023] Here, the manufacturing method of the lower insulating material 40 will be described with reference to FIG. 4. In FIG. 4, for the lower insulating material 40, rectangular thin insulating plates 41 and 46 made of glass epoxy-based FRP are prepared. A slit 43 extending downward is formed in the insulating plate 41 from the center of the upper short side 42a. Similarly, a slit 48 extending upward is formed in the insulating plate 46 from the center of the lower short side 47b. The vertical lengths of the slits 43 and 48 are set to half the height H1 of the insulating plate 41 and the insulating plate 46. Then, the insulating plate 41 and the insulating plate 46 are positioned so as to be orthogonal as shown in FIG. 3, and the insulating plates 41 and 46 are relatively moved in the directions indicated by the arrows 49a and 49b to a position where the slit 43 and the slit 48 engage. The shape after joining is a cross shape in a top view as shown in FIG. 3A. The insulating plate 41 and the insulating plate 46 may be fixed to each other by some fixing means such as adhesion, or may remain unfixed. Further, by fixing the insulating plate 41 to the steel material base 50, a configuration may be adopted such that the insulating plate 41 does not come off from the insulating plate 46.

[0024] Returning to FIG. 3A again. The upper insulating material 30 is also made of FRP in the same manner as the lower insulating material 40, and can be assembled by providing slits in the mutually opposing plates. However, how to combine the plates crossing in a cross shape to form a cross is arbitrary. FIG. 3A shows an example in which the upper insulating material 30 uses a manufacturing method different from that of the lower insulating material 40. That is, insulating plates 31a and 31b having half the size of the insulating plate 36 are joined to both sides of the central portion of a single rectangular insulating plate 36 made of FRP by an adhesive from the left and right directions. In this way, the upper insulating material 30 having a cross shape in a top view is formed using any arbitrary fixing method.

[0025] Of the insulating plates 31 of the upper insulating material 30, the left half 31a is held so as to be sandwiched between the end faces of the wound cores 21 and 22, and the right half 31b is held so as to be sandwiched between the end faces of the wound cores 23 and 24. On the other hand, the front half 36a of the insulating plate 36 is held so as to be sandwiched between the side faces of the wound cores 21 and 23, and the rear half 36b is held so as to be sandwiched between the side faces of the wound cores 22 and 24. The upper insulating material 30 may be in a non-fixed state with respect to the upper clamping fitting 15 (see FIG. 1), and is indirectly fixed by the upper clamping fitting 15 (see FIG. 1) by being sandwiched between the adjacent wound cores 21 and 22, 23 and 24. Incidentally, the upper insulating material 30 may be fixed to the upper clamping fitting 15 (see FIG. 1) using screws, bolts, or other fixing means.

[0026] The steel material base 50 is not formed of a solid member, but is configured by combining a total of 12 small steel plates 51a to 56a, 51b to 56b (the reference numerals not shown are to be referred to FIG. 5A described later). By using the steel material base 50, it is possible to prevent the corners of the wound cores 21 and 22 from sagging due to their own weight, and it can be used as a holding member for the core 2 when the coil 10 is mounted in the assembly process.

[0027] FIG. 3B is a perspective view of the insulating materials 60 and 70 disposed on the magnetic leg portions on the side not penetrated by the coil 10, the wound cores 21 to 24, and the steel base 80 that supports the insulating material 70. The insulating materials 60 and 70 are disposed on the side surfaces of the magnetic leg portions of the wound cores 21 to 24 where the coil 10 is not wound (the released side surfaces where the wound cores are not adjacent), and are formed in a T shape rather than a cross shape when viewed from above. When the upper insulating material 60 is disposed on the right side of the wound cores 23 and 24 (see FIGS. 1 and 2), the insulating plate 61 is disposed between the adjacent end faces of the wound cores 23 and 24. Further, the insulating plate 66 is a side plate provided so as to cover the side surfaces of the exposed wound cores 23 and 24, or functions as a cover material. The same applies to the lower insulating material 70, which is formed by an insulating plate 71 disposed between the adjacent end faces in the stacking direction of the wound cores 23 and 24 (see FIGS. 1 and 2), and a side plate (insulating plate 76) provided so as to cover the side surfaces of the wound cores 23 and 24. Here, since the insulating plates 66 and 76 are not provided in the gaps with the adjacent cores, it is possible to omit the installation. Also, since they are located on the outside, they may be manufactured from a material different from that of the insulating plates 66 and 76. However, in the present embodiment, the insulating plates 66 and 76 are manufactured from the same member as the insulating plates 61 and 71 for the reasons of fixing the insulating plates 61 and 66, 71 and 76, ease of manufacture, and heat resistance requirements.

[0028] The lower insulating material 70 is fixed by the steel base 80 so as to be self-supporting. The steel base 80 is configured by connecting six plates 81 to 86 to an L-shaped base 87 so as to be orthogonal. By using the steel base 80, the corners of the wound cores 23 and 24 (see FIGS. 1 and 2) can be fixed well.

[0029] FIG. 5A is a developed view of the lower insulating material 40 and the steel base 50 shown in FIG. 3A. The lower insulating material 40 is inserted into the steel base 50 in the direction of arrow 59 after the insulating plates 41 and 46 are assembled in a cross shape, and is fixed with bolts (not shown). The steel base 50 is formed by fixing plates 51a to 56a and 51b to 56b so as to extend in orthogonal directions on a substrate 57 made of a thick square flat plate. The substrate 57, the plates 51a to 56a, and 51b to 56b are all made of steel, and they are connected by welding.

[0030] The shapes of plates 51a to 56a and 51b to 56b are approximately right-angled triangles, and the hypotenuse portions are not straight lines but are formed as gentle curved surfaces along the contours of the lower corner portions of the wound cores 21 to 24. Since plates 51a to 56a and 51b to 56b have the same shape, a large number of single parts can be prepared. Plates 51a and 51b are welded so that a gap 51c corresponding to the plate thickness of the insulating plate 46 is formed in the stacking direction. Similarly, after arranging each of the remaining plates 52a to 56a and 52b to 56b, gaps 52c to 56c corresponding to the plate thickness of the insulating plate 46 are formed. The sizes of gaps 52c to 56c are set such that the insulating plate 46 can be inserted in the direction of arrow 59 and there is no rattling after insertion.

[0031] Plates 53a and 54a are formed to have a gap 58a equal to the plate thickness of the insulating plate 41 in the stacking direction, and plates 53b and 54b are formed to have a gap 58b equal to the plate thickness of the insulating plate 41 in the stacking direction. These gaps 58a and 58b are set such that the insulating plate 41 can be inserted in the direction of arrow 59 and there is no rattling after insertion. Bolt holes 53d and 54d (54d is not visible in Fig. 5A) are formed in plates 53b and 54b, and bolts (not shown) are passed through bolt holes 53d, 54d and bolt hole 44 and fixed with nuts (not shown).

[0032] Plates 51a to 53a are arranged in parallel at equal intervals in the stacking direction, and 51b to 53b are arranged in parallel at equal intervals in the stacking direction. Similarly, plates 54a to 56a are arranged in parallel at equal intervals in the stacking direction, and 54b to 56b are arranged in parallel at equal intervals in the stacking direction. As described above, for the steel base 50 to hold one corner of one wound core (for example, wound core 21), only three plates (plates 51a to 53a for wound core 21) are used, so the steel base 50 can be formed to be lightweight compared to the method of manufacturing the steel base 50 with solid steel. Also, since 12 plates 51a to 56a and 51b to 26b are welded to the base 57, a strong self-standing fixing member for the core 2 can be easily realized.

[0033] Figure 5B is a developed view of the lower insulator 70 and the steel base 80 shown in FIG. 3. Near the upper part of the insulating plate 71 of the lower insulator 70, a protrusion 73 corresponding to the thickness of the insulating plate 76 is formed as shown by the dotted line, and is partially engaged with a slit 78 formed downward from the center of the upper side of the insulating plate 76. By fitting a part of the insulating plate 71 (protrusion 73) and a part of the insulating plate (slit 78) in this way, when the insulating plate 71 is bolted to the steel base 80, the movement of the insulating plate 76 in the vertical direction can be more reliably restricted.

[0034] The steel base 80 has substantially the same shape as the shape obtained by cutting the steel base 50 in half in the parallel direction. The only difference from the shape obtained by cutting the steel base 50 in half is that the base 87 is not in the form of a flat plate like half of the substrate 57, but the shape seen from the front or rear is formed in an L shape by a horizontal plate 87a and a vertical plate 87b extending in the vertical direction. Clearances 81a to 86a corresponding to the thickness of the insulating plate 76 are secured between the vertically extending sides (elongated surfaces) of the plates 81 to 86 and the vertical plate 87b. The plates 81 to 83 are arranged in parallel at equal intervals in the stacking direction, and the plates 84 to 86 are arranged in parallel at equal intervals in the stacking direction. Also, the plates 83 and 84 are arranged in parallel with a gap corresponding to the thickness of the insulating plate 71 in the stacking direction. The insulating plate 71 can be inserted into the gap 88 between the plates 83 and 84 in the direction of arrow 89, and the insulating plate 76 can be inserted into the clearances 81a to 86a between the plates 81 to 86 and the vertical plate 87b in the direction of arrow 89. Bolt holes 83c and 84c (84c is not visible in FIG. 5B) are formed in the plates 83 and 84, and by passing bolts (not shown) through the bolt holes 83c, 84c and the bolt hole 74 and fixing them with nuts (not shown), the lower insulator 70 and the steel base 80 are fixed.

[0035] Between the vertical sides of plates 81 to 86 and the vertical plate 87b, gaps 81a to 86a corresponding to the thickness of the insulating plate 76 are formed. By inserting the insulating plate 76 in the direction of arrow 89 between these gaps, the insulating plate 76 is held by the steel base 80. In this way, the steel base 80 is used to fix the wound cores 23, 24 (or 21, 22), and can also be used as a fixing member for the lower insulating material 70.

[0036] Figure 6 is a table showing an example of the combination of materials of the upper insulating materials 30, 60 and the lower insulating materials 40, 70. In Figure 6, Example 1 uses different materials from those of Example 1 shown in Figures 2 to 5. As the upper insulating materials 30, 60, heat-resistant press boards with a heat-resistant temperature of 220°C are used, and as the lower insulating materials 40, 70, insulating materials made of glass epoxy-based FRP with a heat-resistant temperature of 180°C are used. The respective plate thicknesses are, for example, about 1 cm in the case of the amorphous transformer 1 with a height H of about 1 to 2 m. The present invention is not limited only to the materials of Example 1, and the insulating plates may be manufactured from other non-conductive materials. In Example 2, the upper insulating materials 30, 60 are made of ceramics with a very high heat-resistant temperature (for example, much exceeding 200°C), and the lower insulating materials 40, 70 are made of glass substrate epoxy-based FRP with a heat-resistant temperature of 180°C. Example 2 is effective when the temperature rise at the upper part of the wound cores 21 to 24 is particularly severe. It should be noted that even for ceramics, it is important to have a strength above a certain level, and it is important to fully consider that the insulating plates do not crack when the amorphous transformer 1 is subjected to a strong impact when the circuit is opened or closed.

[0037] In Example 3, the upper insulating materials 30, 60 are made of synthetic resin of heat-resistant class B (130°C), and the lower insulating materials 40, 70 are made of synthetic resin of heat-resistant class E (120°C). Depending on the shape of the amorphous transformer and the amount of current flowing, the temperature rise of the wound core may be gentle. In that case, synthetic resins with an even lower heat-resistant temperature (for example, the allowable maximum temperature of heat-resistant class A is 105°C or higher) may be used instead of Example 3.

[0038] In FIG. 6, three material examples were shown, but it is also possible to use insulating materials with heat resistance temperatures other than the examples, or combinations of insulating materials made of other materials than the examples. For example, it is also possible to form an insulating material using glass phenolic FRP. Since most of the upper insulating material 30 and the lower insulating material 40 will be arranged inside the coil 10, it is more preferable to manufacture them with materials having a relative dielectric constant of about 2.5 to 8, not only satisfying a predetermined insulation property and a predetermined heat resistance temperature.

Embodiment

[0039] Next, the amorphous transformer 101 according to the second embodiment of the present invention will be described with reference to FIG. 7. The amorphous transformer 101 shown in FIG. 7 is a three-phase outer iron type. Here, three coils 11 to 13 for the U phase, V phase, and W phase are used. A total of eight amorphous winding cores 21 to 28 as shown in FIG. 7 are used to wind the coils 11 to 13. The winding cores 21 and 22, 23 and 24, 25 and 26, 27 and 28 are arranged such that their end faces are adjacent in the lamination direction. Further, the winding cores 21, 23, 25, 27 are arranged such that their side faces are adjacent to each other at a predetermined interval in the parallel direction, and the winding cores 22, 24, 26, 28 are arranged such that their side faces are adjacent to each other at a predetermined interval in the parallel direction. Note that in FIG. 7, the illustration of the clamping metal fittings corresponding to the upper clamping metal fitting 15 and the lower clamping metal fitting 16 in FIG. 1 is omitted.

[0040] Inside the coil 11, one magnetic leg of the four wound cores 21 to 24 is arranged, and an upper insulator 30 and a lower insulator 40 are arranged between these magnetic legs. The lower insulator 40 is fixed to the steel base 50. Similarly, the other magnetic legs of the two wound cores 23 and 24 and one magnetic leg of the two wound cores 25 and 26 are arranged inside the coil 12. An upper insulator 30 and a lower insulator 40 are arranged between these magnetic legs. This lower insulator 40 is fixed to the steel base 50. Further similarly, the other magnetic legs of the two wound cores 25 and 26 and one magnetic leg of the two wound cores 27 and 28 are arranged inside the coil 13. An upper insulator 30 and a lower insulator 40 are arranged between these magnetic legs. This lower insulator 40 is fixed to the steel base 50. The upper insulator 30 and the lower insulator 40 arranged inside the coils 11, 12, and 13 are the same as those shown in FIGS. 2 to 5.

[0041] Between the two magnetic legs arranged outside the coil 11 among the wound cores 21 and 22, an insulating plate 61 of the upper insulator 60 and an insulating plate 71 of the lower insulator 71 (not visible in FIG. 7) are provided. The lower insulator 70 is fixed to the steel base 80. Similarly, between the magnetic legs arranged outside the coil 11 among the wound cores 27 and 28, an insulating plate 61 of the upper insulator 60 and an insulating plate 71 of the lower insulator 70 are provided. The lower insulator 70 is fixed to the steel base 80.

[0042] By configuring as described above, it becomes possible to manufacture a three-phase outer-iron amorphous transformer 101 using common components used to manufacture the single-phase outer-iron amorphous transformer 1, that is, an amorphous core, insulators (30, 40, 60, 70), and steel bases (50, 80). Similarly, it is also possible to manufacture a two-phase outer-iron amorphous transformer using the common components used to manufacture the single-phase outer-iron transformer 1.

Example

[0043] FIG. 8 is a perspective view of the amorphous transformer 201 according to the third embodiment of the present invention. Except for the upper insulating plates 260 and 261, the other parts have the same configuration as the amorphous transformer 1 shown in FIGS. 1 and 2, and are given the same reference numerals. That is, instead of the upper insulating material 30 shown in FIG. 2, the upper insulating plates 260 and 261 are used. The upper insulating plate 260 is held so as to be sandwiched by the end faces of the wound cores 21 and 22, and the upper insulating plate 261 is held so as to be sandwiched by the end faces of the wound cores 23 and 24. In the third embodiment, no insulating plates are provided between the side faces of the upper portions of the adjacent wound cores 21 and 23 and between the side faces of the upper portions of the wound cores 22 and 24. However, an insulating plate corresponding to the insulating plate 36 in FIG. 2 may be provided.

[0044] The upper insulating plates 260 and 261 are formed in a U-shape in a side view seen from the front or the rear. When the upper insulating plates 260 and 261 are made of a single plate in this way, the effect of also protecting the lap portions (not shown) of the wound cores 21 to 24 can be obtained. A gap of distance S is formed between the upper insulating plates 260 and 261 and the lower insulating materials 40 and 70, respectively, and they are maintained in a non-contact state. Also, the upper insulating plates 260 and 261 are non-contact, and a gap of distance S1 is formed between them. Incidentally, the upper insulating plates 260 and 261 may be configured to be integrally formed with a continuous single plate. By manufacturing the upper insulating plates 260 and 261 and the lower insulating materials 40 and 70 from different materials in this way, it becomes possible to easily satisfy the heat-resistant temperature required for each insulating plate.

[0045] As described above, the present invention has been described based on the embodiments, but the present invention is not limited to the above-described embodiments, and various modifications are possible without departing from the spirit thereof. For example, the lower ends of the upper insulating materials (30, 60, 260, 261) and the upper ends of the lower insulating materials (40, 70) may be configured to be in contact with each other instead of in a non-contact state. Further, the insulating members (30 and 40, 60 and 70) may be formed not in two upper and lower divisions but in three or more divisions in the vertical direction, and insulating materials may be selected so that their heat-resistant temperatures are different from each other.

Description of Reference Numerals

[0046] 1 Amorphous transformer 2 Core 10 - 13 Coil 15 Upper clamping fitting 16 Lower clamping fitting 21 - 28 Wound core 30 Upper insulating material 31, 36 Insulating plate 40 Lower insulating material 41, 46 Insulating plate 43, 48 Slit 44 Bolt hole 50 Steel base 51a - 56a Plate 51b - 56b Plate 51c - 56c Gap 53d Bolt hole 57 Substrate 58a, 58b Gap 60 (Second) upper insulating material 61, 66 Insulating plate 69 Gap 70 (Second) lower insulating material 71, 76 Insulating plate 73 Protrusion 74 Bolt hole 78 Slit 80 Steel base 81 - 86 Plate 81a - 86a Gap 83c, 84c Bolt hole 87 Base 87a Horizontal plate 87b Vertical plate 88 Gap 101, 201 Amorphous transformer 260, 261 Upper insulating plate

Claims

1. An amorphous transformer comprising a plurality of wound cores made of amorphous material arranged in a stacking direction and a parallel direction, a support member for making the wound cores self-supporting, a coil formed by winding around a leg of any one of the plurality of wound cores, and an upper clamping fitting and a lower clamping fitting for fixing the wound cores, wherein an insulating material is provided to keep a constant interval between end faces of legs of the wound cores adjacent in the stacking direction and between side faces of legs of the wound cores adjacent in the parallel direction, the insulating material is formed by dividing it into a lower insulating material fixed to the support member and an upper insulating material having a different heat-resistant temperature from the lower insulating material. The amorphous transformer is characterized by this.

2. the insulating material is made of resin or resin containing reinforcing fibers, the upper insulating material is fixed by the upper clamping fitting so as to have a gap from the lower insulating material, the amorphous transformer according to claim 1, wherein the heat-resistant temperature of the upper insulating material is higher than the heat-resistant temperature of the lower insulating material.

3. the upper insulating material and the lower insulating material are formed by forming a flat plate made of reinforced fiber plastic into a T shape or a cross shape in a top view, the upper insulating material and the lower insulating material in contact with a magnetic leg passing through the coil are in a cross shape, the amorphous transformer according to claim 2, wherein the upper insulating material and the lower insulating material in contact with a magnetic leg not passing through the coil are in a T shape.

4. the upper end position of the cross-shaped lower insulating material and the upper end position of the T-shaped lower insulating material are located above the center of gravity position in the vertical direction of the wound core. The amorphous transformer according to claim 3 is characterized by this.

5. For the cross-shaped upper insulating material and the cross-shaped lower insulating material, two rectangular plates with a slit formed longitudinally extending from the center position of one short side of the rectangular plate in the longitudinal direction are prepared, and they are assembled in a state where they intersect so that the slits of the two rectangular plates fit together to form a cross shape. The amorphous transformer according to claim 4 is characterized by this.

6. the T-shaped upper insulating material and the cross-shaped lower insulating material are each joined by bonding two plates. The amorphous transformer according to claim 5 is characterized by this.

7. the upper insulating material is a fiber-reinforced plastic having a heat-resistant temperature of 105 ° C or higher. The amorphous transformer according to claim 6 is characterized by this.

8. A plurality of amorphous wound cores arranged side by side in the stacking direction and / or the parallel direction, a support member for making the wound cores self-supporting, a coil formed by winding across the magnetic legs of adjacent wound cores, and an upper clamp fitting and a lower clamp fitting for fixing the upper and lower sides of the wound cores, wherein a plate-like first insulating member is interposed in the vertical surfaces facing each other so that adjacent surfaces of the plurality of wound cores wound around the coil are held at a constant interval, the first insulating member is made of a reinforced fiber plastic and is formed by being divided into a first upper insulating material in contact with the upper side of the wound core and a first lower insulating material in contact with the lower side of the wound core, the position of the division is set to be above the centroid position of the wound core, and the heat-resistant temperature of the first upper insulating material is higher than the heat-resistant temperature of the first lower insulating material, characterized by an amorphous transformer.

9. The amorphous transformer according to claim 8, wherein the first upper insulating material is fixed by an upper clamp fitting, and the first lower insulating material is fixed by the support member.

10. In the magnetic legs where the wound cores are arranged adjacent to each other in the stacking direction and the parallel direction, the first upper insulating materials provided between the magnetic legs of the wound cores wound by the coil are arranged so as to cross in a cross shape, The amorphous transformer according to claim 9, wherein the first lower insulating materials provided between the magnetic legs of the wound cores wound by the coil are arranged so as to cross in a cross shape.

11. A plate-like second insulating member is provided on the vertical surface on the stacking direction side of the magnetic legs that are not wound by the coil and where the wound cores are not adjacent to each other in the parallel direction, The amorphous transformer according to claim 10, wherein the second insulating member is formed with the same thickness as the first insulating member and is fixed to the support member in a state where it is not penetrated by the coil.

12. The second insulating member is made of a reinforced fiber plastic and is formed by being divided into a second upper insulating material in contact with the upper side of the wound core and a second lower insulating material in contact with the lower side of the wound core, The amorphous transformer according to claim 11, wherein the position of the division is set to be above the centroid position of the wound core, and the heat-resistant temperature of the second upper insulating material is higher than the heat-resistant temperature of the second lower insulating material.

13. An insulating side plate is provided on the vertical side surface of the magnetic leg portion where the wound iron core is not adjacent in the parallel direction. The amorphous transformer according to claim 12, wherein the side plate is fixed to the support member. **Claim 14** The amorphous transformer according to claim 13, wherein the side plate is formed by being divided into an upper side plate that contacts the upper side of the wound iron core and a lower side plate that contacts the lower side of the wound iron core.

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