Method for the arrangement of electrical windings in a core of a transformer made of amorphous material and closed into a loop and support apparatus for the execution of the aforesaid method
The method using a support apparatus for amorphous cores stabilizes flexible strips during winding insertion, addressing the challenge of constructing transformers with amorphous cores by reducing time, cost, and defects.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- TRAFO ELETTRO SRL
- Filing Date
- 2025-11-17
- Publication Date
- 2026-05-21
AI Technical Summary
The construction of transformers with amorphous cores is challenging due to the flexible strips being superimposed and folded into a loop, making it difficult to insert electrical windings without disrupting the closed loop structure.
A method involving the use of a support apparatus with specific configurations to facilitate the arrangement of electrical windings by folding and securing flexible strips on the amorphous core, allowing for precise and repetitive insertion.
Reduces construction time and costs, enhances precision, and minimizes defects in transformers with amorphous cores by stabilizing the flexible strips during winding insertion.
Smart Images
Figure IB2025061721_21052026_PF_FP_ABST
Abstract
Description
[0001] METHOD FOR THE ARRANGEMENT OF ELECTRICAL WINDINGS IN A CORE OF A TRANSFORMER MADE OF AMORPHOUS MATERIAL AND CLOSED INTO A LOOP AND SUPPORT APPARATUS FOR THE EXECUTION OF THE AFORESAID METHOD.
[0002] DESCRIPTION
[0003] The present invention relates to a method for the arrangement of electrical windings in a core of a transformer made of amorphous material and closed into a loop.
[0004] The invention also relates to a support apparatus for the execution of the aforesaid method.
[0005] It is known that, for the construction of resin-type electrical transformers, the use of amorphous cores made of metal alloy that does not have a regular crystalline structure allows to obtain numerous advantages over transformers provided with traditional cores made of crystalline silicon steel sheets.
[0006] In particular, unlike traditional cores, the amorphous cores do not have an ordered atomic structure. The alloy is rapidly cooled during production, preventing the formation of crystals and giving rise to a disordered, i.e. amorphous, structure.
[0007] This, advantageously, reduces eddy currents (Foucault currents), as the resistivity of the material increases. This helps to reduce eddy current losses in the core.
[0008] In addition, the amorphous cores have significantly lower magnetic losses than the traditional cores, especially at low frequency. This results in a higher energy efficiency of the transformer, with a reduction in no-load losses.
[0009] Furthermore, the amorphous structure allows the material to be magnetized and demagnetized more quickly, which improves the performance of the transformer, especially in applications that require a rapid response.
[0010] Therefore, the use of amorphous cores in transformers results in a reduction of no-load losses by up to 70% compared to the traditional cores, which leads to significant energy savings, especially in transformers operating for long periods under partial load.
[0011] There is also a lower environmental impact, as lower losses mean lower CO2emissions associated with power generation.
[0012] In addition, the reduced losses generate less heat, improving life of the transformer and reducing the need for cooling. To date, these advantages push manufacturers of resin-type electrical transformers to opt for making their products with amorphous cores rather than traditional-type cores.
[0013] However, in practice, the production of such transformers with amorphous cores is more difficult than the production of transformers with traditional-type cores. In particular, the transformer manufacturing companies usually buy transformer cores that have been already composed by third parties and their task is to assemble the transformer, that is to say, to provide mainly for the insertion of the electrical windings of the transformer at the various branches of the core. In the case of traditional transformers, which require the core to be made up of several separate sections, each composed of rigid metal sheets, this operation of inserting the electrical windings involves removing the sheets that make up the upper section of the core, so as to leave the upper ends of the various branches of the same core free, thus allowing the insertion of the various windings from above at each of the aforesaid branches, and then to reposition said upper section in such a way as to restore the closed loop geometry of the core itself.
[0014] This procedure cannot be replicated for the construction of transformers provided with amorphous cores since, as known, the amorphous cores are defined by a plurality of flexible strips in amorphous material superimposed on each other and folded in such a way that each one is closed into a loop, so as to define an overall structure of the core with closed loop of substantially rectangular shape.
[0015] In particular, the two ends of each of said flexible strips folded into a closed loop are joined together at one side of said core.
[0016] Incidentally, for the three-phase transformers, the amorphous core, again by folding these flexible strips, is made with a structure with double loop which is closed in such a way as to define three branches on which to arrange the three electrical windings.
[0017] Therefore, it is clear that in the case of amorphous cores it is not possible to remove an upper section to leave free the ends of the various branches on which to arrange the electrical windings.
[0018] For this reason, therefore, disadvantageously, when the amorphous core is supplied already composed by a third party, the company that has to make the transformer has greater difficulties in arranging the aforesaid electrical windings at the various branches of the core.
[0019] The object of the present invention is to propose a method for the arrangement of electrical windings in a core of a transformer made of amorphous material, which can facilitate this insertion and therefore facilitate the construction of a transformer with amorphous core.
[0020] Therefore, it is an object of the invention to propose a method that allows to reduce the times for the construction of a transformer with amorphous core. Consequently, it is an object of the invention to propose a method that allows to reduce the costs for the construction of the aforesaid transformers.
[0021] It is also an object of the invention to propose a method that allows this operation of arranging the electrical windings on the amorphous core to be carried out in a more precise and repetitive manner.
[0022] This advantageously involves the reduction of possible construction defects of the transformer and rejects.
[0023] The above objects are achieved by the method for the arrangement of electrical windings in a core of a transformer made of amorphous material according to claim 1.
[0024] Further characteristics of the method according to claim 1 are described in the dependent claims.
[0025] These objects are also achieved by the support apparatus for the execution of the aforesaid method, in accordance with claim 6.
[0026] The task and the aforesaid objects, together with the advantages that will be mentioned below, are highlighted by the description of some embodiments of the invention, which are given, by way of indication but not limitation, with reference to the attached drawing tables, where:
[0027] - fig. 1 depicts an amorphous core of a transformer;
[0028] - fig. 1 a depicts a first detail of the amorphous core of fig. 1 ;
[0029] - fig. 1 b depicts a second detail of the amorphous core of fig. 1 ;
[0030] - fig. 2 depicts a transformer provided with the amorphous core of fig. 1 ;
[0031] - figs. 3a to 3p depict the steps of the method of the invention in sequence; - fig. 4 depicts in axonometric view a first embodiment of the support apparatus of the invention according to a first configuration for the execution of the method of the invention;
[0032] - fig. 5 depicts the section according to the section plane V-V of fig. 4 of the support apparatus of fig. 4; - fig. 6 depicts the support apparatus of fig. 4 in a second configuration;
[0033] - fig. 7 depicts in axonometric view a second embodiment of the support apparatus of the invention according to a first configuration for the execution of the method of the invention;
[0034] - fig. 8 depicts the support apparatus of fig. 7 in a second configuration;
[0035] - fig. 9 depicts the support apparatus of fig. 7 in a third configuration;
[0036] - figs, from 10a to 10n depict the steps of the method of the invention in sequence using the support apparatus according to figs. 7-9.
[0037] The steps of the method of the invention, for the arrangement of electrical windings 101 in a core 102 made of amorphous material and closed into a loop of a transformer 100, are depicted in sequence in figs, from 3a to 3p, to which reference will be made hereinafter.
[0038] As mentioned above, as can be observed in figs. 1, 1a and 1 b, these amorphous cores 102 are defined by a plurality of flexible strips 200 in amorphous material superimposed on each other and folded so as to define a closed loop of substantially rectangular shape, where the two ends 200a and 200b of each of the flexible strips 200 folded into a closed loop are joined together at one side 102a of said amorphous core 102.
[0039] Furthermore, as mentioned above and visible in fig. 1, for the three-phase transformers, which evidently require three electrical windings, this amorphous core 102 has a closed double loop shape so as to define three substantially parallel branches on which to arrange the aforesaid three electrical windings. Even more in detail, such amorphous cores for three-phase transformers are obtained by composing three pluralities of flexible strips 200, each folded into a closed loop and assembled in such a way as to define the double closed loop shape visible in fig. 1.
[0040] According to the invention, the method first of all provides a step a) consisting in arranging the amorphous core 102 closed in a loop in a vertical position with the side 102a in which the junctions between the two ends 200a and 200b of each flexible strip 200 are defined, and arranged horizontally and facing upwards, as can be observed in fig. 3a.
[0041] The next step of the method, indicated with b) and depicted in fig. 3b, provides for disassociating the ends 200a and 200b of each flexible strip 200, so that the various flexible strips 200 can be moved subsequently.
[0042] In fact, step c) of the method, depicted in fig. 3h, provides for folding, one by one, the flexible strips 200 so as to bring their end portion 201 arranged horizontally into a vertical position.
[0043] According to the preferred embodiment of the invention described herein, before performing said step c), the method, with the aid of a support apparatus 300 and 400, described below, provides for performing two further steps indicated with b1) and b2).
[0044] In particular, step b1 ) provides for preparing an aforesaid support apparatus 300 in a vertical position and at each of the two vertical sides 102b and 102c of the amorphous core 102, as visible in figs. 3c and 3d. In detail, said support apparatus 300 is prepared at each of the two vertical sides 102b and 102c in such a way that its lower end is located halfway, or rather at the upper third of said vertical sides 102b and 102c. The advantage of this arrangement will be clarified below. Even more particularly, as can be observed in figs. 4 to 6, each of these support apparatus 300, according to a first embodiment of the invention, is defined by a structure with substantially longitudinal development in which a main portion 301 and at least a top portion thereof 303 defining a housing 302 with a “C”-shaped section are identified. The positioning of this support apparatus 300 at each of the two vertical sides 102b and 102c of the amorphous core 102 provides for associating the main portion 301 at the aforesaid vertical sides 102b and 102c, while the top portion 303 extends upwards with respect to the same amorphous core 102, as visible in fig. 3d.
[0045] It is not excluded that, according to an embodiment variant of the method of the invention, only one support apparatus 300 is arranged at only one of the two vertical sides 102b or 102c of the amorphous core 102.
[0046] This at least one top portion 303 of the support apparatus 300 is tiltable with respect to its main portion 301, as visible in fig. 6.
[0047] Therefore, specifically, the support apparatus 300 is prepared at each of the two vertical sides 102b and 102c, with the main portion 301 associated with the aforesaid vertical sides 102b or 102c so that the folding section between the same main portion 301 and the top portion 303 is arranged substantially at the upper end of each of the two vertical sides 102b and 102c, where the lateral curvatures of the amorphous core 102 are defined, as can be observed in fig. 3c.
[0048] With regard to step b2), it provides for tilting this top portion 303 with respect to the main portion 301 into a horizontal position so that for this top portion 303 the housing 302 has the opening facing upwards and in such a way as to define a horizontal rest plane 304 which is substantially at the same height as the upper end of each of the two vertical sides 102b and 102c, where the lateral curvatures of the amorphous core 102 are defined, as depicted in fig. 3e.
[0049] According to this preferred embodiment of the method of the invention, as depicted in fig. 3f, the folding step c) then provides for folding each flexible strip 200 in such a way that, at least for the longer flexible strips, the corresponding end portion 201 is placed resting on the aforesaid horizontal rest plane 304. This advantageously makes it possible to discharge the weight of the flexible strips 200 during their accumulation on the support apparatus 300, preventing these strips from being loosened, or at least, undesirably displaced by the aforesaid support apparatus 300.
[0050] Once all the flexible strips 200 have been folded, the method first provides for securing the same flexible strips 200 to the support apparatus 300, as depicted in fig. 3g. Preferably, this operation can be implemented by means of belts 500 or different locking means. This advantageously prevents the flexible strips 200 from coming out of the housing 302 or at least from being able to be displaced with respect to the support apparatus 300.
[0051] Subsequently, the method, again according to step c), provides for tilting the top portion 303 again so as to return it into a vertical position, aligned with the main portion 301, as depicted in fig. 3h.
[0052] At this point, therefore, the amorphous core 102 is open and the various flexible strips 200 are secured to the support apparatus 300.
[0053] This allows to perform the next step of the method, indicated with d) and depicted in fig. 3i, which provides for inserting from the top of the flexible strips 200 arranged vertically, in particular from the top of the support apparatus 300, the electrical winding 101. Fig. 3I depicts the three electrical windings 101 arranged on the amorphous core 102 immediately after the execution of step d). The method of the invention provides, subsequently, to perform step e) which consists in folding, one by one, the flexible strips 200 so as to bring them from the vertical position to their previous horizontal position so as to redefine said closed loop, as depicted in fig. 3o.
[0054] In particular, this step e), according to the preferred embodiment of the method described herein, provides for tilting the top portion 303 of the support apparatus 300 again so as to arrange it in the aforesaid horizontal position as depicted in fig. 3m, to disassociate the flexible strips 200 from the support apparatus 300, as depicted in fig. 3n, removing any belts 500, and only at this point to proceed with folding, one by one, the flexible strips 200 so as to bring them from said vertical position to their previous horizontal position, as precisely depicted in fig. 3o, so as to redefine the closed loop. This procedure according to step e), with the aid of the support apparatus 300, advantageously allows to keep in a stable position the plurality of flexible strips 200, therefore avoiding loosening or any unwanted movements, while folding, one by one, the same flexible strips 200.
[0055] Finally, the method of the invention with the step indicated with f) provides for joining again the ends 200a and 200b of each of said flexible strips 200, so as to restore the integrity of the amorphous core 102, as depicted in fig. 3p. Clearly, at the conclusion of the method according to the invention, and therefore after the aforesaid step f), it is provided for removing the support apparatuses 300 from the amorphous core 102 of the transformer 100, as depicted in fig. 2. Since, as mentioned above, said support apparatuses 300 are prepared at each of the two vertical sides 102b and 102c in such a way that their lower end is located halfway, or rather at the upper third of said vertical sides 102b and 102c, this removal operation is facilitated.
[0056] According to an embodiment variant, usually used for amorphous cores 102 of large transformers 100, the support apparatus, as visible in figs. 7 to 9, where it is indicated with 400, could comprise the aforesaid main portion, now indicated with 401, an intermediate portion 405 tiltable with respect to said main portion 401 and the aforesaid top portion, now indicated with 403 tiltable with respect to the intermediate portion 405.
[0057] In this case, therefore, the method of the invention, as for the preferred embodiment and whose steps are depicted in the sequence of figures from 10a to 10n:
[0058] - provides, during step b1), for preparing the aforesaid support apparatus 400 at each of the two vertical sides 102b and 102c of the amorphous core 102, with the main portion 401 associated with the aforesaid vertical sides 102b and 102c so that the folding section between the same main portion 401 and the intermediate portion 405 is arranged substantially at the upper end of each of the two vertical sides 102b and 102c, where the lateral curvatures of the amorphous core 102 are defined, as can be observed in fig. 10a; - provides, during step b2) and as can be observed in fig. 10c, for tilting only the top portion 403 with respect to the main portion 401 and the intermediate portion 405, keeping the intermediate portion 405 aligned vertically with the main portion 401, while
[0059] - it provides, during step e), for tilting the top portion 403 jointly with the intermediate portion 405 with respect to the main portion 401 so as to arrange the top portion 403 together with the intermediate portion 405 in said horizontal position substantially at the same height as the upper end of each of the two vertical sides 102b and 102c, where the lateral curvatures of the amorphous core 102 are defined, as depicted in fig. 10i.
[0060] This sequence of operations, with the use of the support apparatus 400, advantageously allows to facilitate the operations of folding the flexible strips 200 and inserting the electrical windings 101 into the amorphous core 102, in the case of large amorphous cores 102.
[0061] In particular, the fact that during step b2) it is provided to tilt only the top portion 403, while keeping the main portion 401 and the intermediate portion 405, in a vertical position, allows, on the one hand, to define a horizontal rest surface 404 sufficient to discharge the weight of the flexible strips 200 during their accumulation on the support apparatus 400, thus avoiding that these strips undergo a loosening, but at the same time it allows to limit the size of this rest surface 404 and therefore the portion of flexible strips 200 resting on it, in such a way as not to make the subsequent operation, depicted in fig. 10f , of folding vertically the top portion 403 together with the ends of the flexible strips 200 for the subsequent insertion of the electrical windings 101 , as depicted in figures 10g and 10h, too burdensome. In fact, in the case of large amorphous cores 102, if during step b2) the intermediate portion 405 and the top portion 403 were tilted jointly, and the flexible strips 200 were placed to rest on both these portions, the effort to then return these portions to a vertical position, together with the flexible strips 200, would become very considerable and burdensome. Otherwise, when the electrical windings 101 have been inserted, and it is necessary to close the amorphous core 102, the fact that during step e) it is provided for horizontally tilting the intermediate portion 405 jointly with the top portion 403 allows to facilitate the manual operation of repositioning, one by one, the flexible strips 200 in the closed position of the amorphous core 102, since in this way the flexible strips 200 in this step find a large rest surface that allows to keep their position on the support apparatus 400 stable. In fact, if otherwise during this step only the top portion 403 were folded horizontally, the effort that an operator should exert to pick and reposition for closing, one by one, the flexible strips 200, while keeping the other flexible strips 200 stationary in a vertical position, would be much more considerable and burdensome.
[0062] As mentioned above, the support apparatus for the execution of the method of the invention is also part of the invention.
[0063] In particular, according to a first embodiment of said support apparatus 300 of the invention, visible in figs. 4 to 6, it comprises a structure with substantially longitudinal development in which a main portion 301 and at least one top portion 303 defining a housing 302 with a “C”-shaped section and tiltable with respect to its main portion 301 are identified.
[0064] In particular, according to this first embodiment of the invention, the top portion 303 is connected to the main portion 301 by means of at least one mechanical hinge 306 so as to make the top portion 303 tiltable with respect to its main portion 301.
[0065] In accordance with a second embodiment of the support apparatus 400 of the invention, as seen above and as visible in figs. 7 to 9, it also comprises an intermediate portion 405 defined between the main portion 401 and the top portion 403, where said intermediate portion 405 is tiltable with respect to the main portion 401, while the top portion 403 is tiltable with respect to the intermediate portion 405.
[0066] Also in this case the top portion 403 is connected to the intermediate portion 405 by means of at least a first mechanical hinge 406 so as to make the top portion 403 tiltable with respect to its intermediate portion 405, while the intermediate portion 405 is connected to the main portion 401 by means of at least a second mechanical hinge 407 so as to make the intermediate portion 405 tiltable with respect to its main portion 401.
[0067] Practically, it has been established that the invention achieves all the intended objects.
[0068] In particular, with the invention the object of proposing a method for the arrangement of electrical windings in a core of a transformer made of amorphous material, which can facilitate this insertion and therefore facilitates the construction of a transformer with amorphous core, is achieved.
[0069] Therefore, the object of proposing a method that allows to reduce the times for the construction of a transformer with amorphous core is also achieved. Consequently, the object of proposing a method that allows to reduce the costs for the construction of the aforesaid transformers is also achieved.
[0070] The object of proposing a method that allows this operation of arranging the electrical windings on the amorphous core to be carried out in a more precise and repetitive manner is also achieved.
[0071] This advantageously involves the reduction of possible construction defects of the transformer.
Claims
CLAIMS1) Method for the arrangement of electrical windings (101) in an amorphous core (102) of a transformer (100) made of amorphous material and closed into a loop, said amorphous core (102) being defined by a plurality of flexible strips (200) in amorphous material superimposed on each other and folded so as to define a closed loop of substantially rectangular shape, the two ends (200a, 200b) of each of said flexible strips (200) folded into a closed loop being joined together, said method being characterized by providing the following steps:a) arranging said amorphous core (102) closed into a loop in a vertical position with the side (102a) where said junctions are defined arranged horizontally and facing upwards;b) disassociating said ends (200a, 200b) of each flexible strip (200);c) folding said flexible strips (200) one by one so as to bring their horizontally arranged end portion (201) into a vertical position;d) inserting one of said electrical windings (101) from the top of said flexible strips (200) arranged vertically;e) folding said flexible strips (200) one by one so as to bring them from said vertical position to their previous horizontal position so as to redefine said closed loop;f) once all said flexible strips (200) are arranged in said horizontal position, joining again said ends (200a, 200b) of each of said flexible strips (200). 2) Method according to claim 1 , characterized in that prior to said step c) it is provided for:b1 ) preparing at least one support apparatus (300, 400), defined by a structure with substantially longitudinal development in which a main portion (301, 401) is identified, in a vertical position and at a vertical side (102b, 102c) of said amorphous core (102) so that said main portion (301, 401) is associated with said vertical side (102b, 102c) of said amorphous core (102), said support apparatus (300, 400) providing at least one top portion (303, 403) defining a “C” -section housing (302, 402), said top portion (303, 403) being tiltable with respect to its main portion (301, 401);b2) tilting said top portion (303, 403) with respect to said main portion (301, 401) of said support apparatus (300, 400) into a horizontal positionso that for said top portion (301, 401) said housing (302, 402) has the opening facing upwards and so as to define a horizontal rest plane (304, 404);said method also providing that during said folding step c) the end portion (201) of each of said flexible strips (200) is placed resting on said horizontal rest plane (304, 404), and once all said flexible strips (200) have been folded, it is provided for:- securing said flexible strips (200) to said support apparatus (300, 400);- tilting said top portion (303, 403) so as to return it into a vertical position aligned with said main portion (301, 401) of said support apparatus (300, 400);said method also providing that during said folding step e):- the top portion (303, 403) of said support apparatus (300, 400) is again tilted so as to be arranged in said horizontal position;- said flexible strips (200) are disassociated from said support apparatus (300, 400);- said flexible strips (200) are folded one by one so as to bring them from said vertical position to their previous horizontal position so as to redefine said closed loop.3) Method according to claim 2, characterized in that following operation f) said support apparatus (300, 400) is removed from the amorphous core (102) of said transformer (100).4) Method according to any one of the preceding claims, characterized in that operations c) to f) are performed for both vertical sides (102b, 102c) of said amorphous core (102).5) Method according to claim 2 or according to any one of claims 3 or 4 in combination with claim 2, characterized in that said support apparatus (400) comprises said main portion (401), an intermediate portion (405) tiltable with respect to said main portion (401 ) and said top portion (403) tiltable with respect to said intermediate portion (405), said method providing that during said step b2) said top portion (403) is tilted with respect to said main portion (401) and to said intermediate portion (405), keeping said intermediate portion (405) vertically aligned with said main portion (401 ), said method further providing that during said step e) said top portion (403) is tilted jointly with said intermediate portion (405) with respect to said main portion (401) so as to arrange said topportion (403) together with said intermediate portion (405) in said horizontal position.6) Support apparatus (300, 400) for the execution of the method according to claim 2 or according to any one of claims 3 to 5 in combination with claim 2, characterized in that it comprises a structure with substantially longitudinal development in which a main portion (301, 401) and at least one top portion (303, 403) defining a housing (302, 402) with a “C”-shaped section are identified, said top portion (303, 403) being tiltable with respect to its main portion (301, 401).7) Support apparatus (400) according to claim 6, characterized in that it comprises an intermediate portion (405) defined between said main portion (401) and said top portion (403) and tiltable with respect to said main portion (401), said top portion (403) being tiltable with respect to said intermediate portion (405).8) Support apparatus (300) according to claim 6, characterized in that said top portion (303) is connected to said main portion (301) by means of at least one mechanical hinge (306) so as to make said top portion (303) tiltable with respect to its main portion (301).9) Support apparatus (400) according to claim 7, characterized in that said top portion (403) is connected to said intermediate portion (405) by means of at least one first mechanical hinge (406) so as to make said top portion (403) tiltable with respect to its main portion (401) and said intermediate portion (405) is connected to said main portion (401) by means of at least one second mechanical hinge (407) so as to make said intermediate portion (405) tiltable with respect to its main portion (401).