Magnetic Circuit Loop Winding With Oblique Cut Half-Rolls
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Solution Overview
Problem
Existing methods for manufacturing magnetic circuit loops in power transformers result in material waste and high production costs due to burrs and material scraps, particularly when using laser cutting or edge chamfering techniques.
Innovation Solution
A method involving the cutting of a magnetic strip into half-rolls with opposite boundary orientations, followed by alignment and shape transition on mandrels to form loops, minimizing material waste and costs by eliminating the need for edge chamfering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser cutting is used to adjust the width of the magnetic strip band upstream of winding, then the oblique junction surface can be delimited, but burrs and irregular material excesses appear along the cutting edge causing short-circuits and undesirable spaces between layers
Solution Approach 1:
The harmful burrs and material excesses are removed through a controlled chamfering process that extracts only the necessary portions. The method separates the cutting function (laser) from the finishing function (chamfering), allowing each to optimize its performance without the other's negative effects.
Solution Approach 2:
The chamfering operation is performed as a preliminary action before winding, preparing the magnetic strip band by removing burrs and creating the correct oblique surface geometry in advance. This ensures that when winding occurs, the material is already in its final required configuration.
2Manufacturing precision
If chamfering by machining, electroerosion, or water jet cutting is used after winding, then surface defects are avoided, but expensive material scraps are generated and production time increases
Solution Approach 1:
The chamfering operation is performed as a preliminary action before winding, preparing the magnetic strip band by removing burrs and creating the correct oblique surface geometry in advance. This ensures that when winding occurs, the material is already in its final required configuration.
Solution Approach 2:
The method changes the parameters of the cutting process by using laser cutting with specific power and speed settings followed by controlled chamfering, rather than traditional machining methods. This combination allows for minimal material removal while achieving the desired surface quality.
3Manufacturing precision
If traditional winding and chamfering methods are used, then loops with oblique junction surfaces can be formed, but production costs increase due to material waste and extensive processing
Solution Approach 1:
The method merges the width adjustment and chamfering operations into a single integrated process sequence. The laser cutting and chamfering are combined in one workflow, eliminating the need for separate machining operations and reducing overall production time and cost.
Solution Approach 2:
The invention replaces traditional mechanical chamfering methods (machining, electroerosion, water jet cutting) with a laser-based system followed by minimal chamfering. This substitution reduces material waste, decreases processing time, and lowers production costs while maintaining the required precision.
Data Source
AI summary
A method for manufacturing magnetic circuit loops for a multi-phase transformer from a magnetic strip including: a) providing a magnetic strip of constant width in a roll wound around a first circular mandrel and extending along a longitudinal axis; b) cutting the roll into a first and a second half-roll each having a longitudinal axis comprising a respective boundary surface formed once it is separated from the other half-roll, the roll being cut slantwise at an angle θ relative to the longitudinal axis, such that the first half-roll constitutes a first loop having its boundary surface outwardly oriented relative to its longitudinal axis, while the boundary surface of the second half-roll is oriented opposite to the boundary surface of the first half-roll; c) aligning the first and second half-rolls to form two loops, including at least one sub-step of reversely unwinding and rewinding the second half-roll on a mandrel.