阅读说明：本技术 一种高效低能耗变压器 (High-efficiency low-energy-consumption transformer ) 是由 姜诚渊 姜嵘轩 姜斌 于 2021-06-15 设计创作，主要内容包括：一种高效低能耗变压器,包括硅钢片、上铁轭、下铁轭、铁芯柱和线圈,铁芯柱由众多硅钢片按序积叠而成；组成铁芯柱的众多硅钢片分成若干单元,每个单元由宽度不一的多组硅钢片构成；所有硅钢片呈发射状向心排列,且多组硅钢片的每一组由宽度一致的多片硅钢片叠积而成,所有硅钢片的长度相一致；上铁轭、下铁轭的硅钢片的长度、宽度相一致。本发明变压器具有如下优点：铁芯涡流损耗小、消除了线圈局部温度过高现象,减缓线圈绝缘体老化速度、材料利用率高生产成本低、铁芯柱不变形机械钢性强,设计绝缘距离能得到可靠保证的优点,大大提高了变压器运行的可靠性和时效性。(A high-efficiency low-energy transformer comprises silicon steel sheets, an upper iron yoke, a lower iron yoke, an iron core column and a coil, wherein the iron core column is formed by stacking a plurality of silicon steel sheets in sequence; a plurality of silicon steel sheets forming the iron core column are divided into a plurality of units, and each unit is composed of a plurality of groups of silicon steel sheets with different widths; all the silicon steel sheets are arranged radially and centripetally, each group of the multiple groups of silicon steel sheets is formed by stacking a plurality of silicon steel sheets with the same width, and the lengths of all the silicon steel sheets are the same; the length and the width of the silicon steel sheets of the upper iron yoke and the lower iron yoke are consistent. The transformer of the invention has the following advantages: the iron core has the advantages of small eddy current loss, elimination of the phenomenon of overhigh local temperature of the coil, reduction of the aging speed of a coil insulator, high material utilization rate, low production cost, strong mechanical rigidity of the iron core column without deformation, reliable guarantee of the designed insulation distance and great improvement of the reliability and the timeliness of the operation of the transformer.)

1. The utility model provides a high-efficient low energy consumption transformer, includes silicon steel sheet (1), goes up indisputable yoke (6), indisputable yoke (9) down, iron core post (7) and coil (10), and iron core post (7) are formed by piling up in order numerous silicon steel sheet (1), characterized by: a plurality of silicon steel sheets (1) forming the iron core column (7) are divided into a plurality of units (18), and each unit (18) is composed of a plurality of groups (19) of silicon steel sheets (1) with different widths; all the silicon steel sheets (1) are arranged in a radial centripetal manner.

2. A high efficiency, low energy consumption transformer as claimed in claim 1, wherein: each group (19) of the multiple groups of silicon steel sheets (1) is formed by stacking multiple silicon steel sheets (1) with consistent width.

3. A high efficiency, low energy transformer as claimed in claim 1 or 2, wherein: the lengths of all the silicon steel sheets (1) are consistent.

4. A high efficiency, low energy transformer as claimed in claim 1 or 2, wherein: the lengths and the widths of the silicon steel sheets forming the upper iron yoke (6) and the lower iron yoke (9) are consistent.

Technical Field

The invention relates to a transformer, in particular to a transformer with a novel iron core column structure.

Background

In the conventional power equipment such as a transformer containing an excitation core, a core column of the magnetic core is formed by stacking a plurality of silicon steel sheets, the specific cross-sectional shape is shown in fig. 1, 2, 3, 4 and 5, and the silicon steel sheets 1 in the drawing are divided into a flat-folding type, a three-dimensional type and a gradually-opening type in the lamination direction. The prior art power equipment such as an excitation iron core transformer has the following problems:

one, the iron core eddy current loss (load loss) is large

Due to the existence of the skin effect of the electric conductor and the edge derivative effect of the magnetizer, the excitation characteristic of the magnetically excited iron core can not be fully reflected when the rated power is not reached, the excitation characteristic reaction is very weak, the influence of the excitation line on the iron core column is very small, and the actual loss of the transformer under the loaded state can not be measured by only adding impedance voltage and short-circuit rated current in the traditional test method; when the device is loaded with a rated load, the excitation characteristic is reflected very strongly. The core limb is used as an independent magnetizer with a coil, and a magnetic excitation line generated after the strong excitation characteristic reaction passes through a silicon steel sheet plane of the magnetic iron core (as shown in fig. 6): when the magnetic excitation line 2 passes through the plane of the silicon steel sheet, the higher the perpendicularity of the diffraction direction 3 of the magnetic excitation line and the plane of the silicon steel sheet is, the larger the eddy current loss is, and the eddy current loss in the sheet in the area is increased suddenly. According to verification, under the long-term full-load operation state of the transformer, the eddy current loss of the silicon steel sheets in the area, perpendicular to the magnetic excitation wire 2, of the magnetic conduction iron core under the action of the edge derivative effect is extremely high, the heating phenomenon of the area is serious, the iron core of the silicon steel sheets in the area glows, the surface of the silicon steel sheets is subjected to insulation carbonization (the iron core heating carbonization positions 4 and 41), short circuit between the silicon steel sheets in the area is caused, and the eddy current loss is increased in a square shape sharply. And the silicon steel sheet close to the main-level area of the iron core column is in good condition because few magnetic excitation lines parallel to the magnetic excitation line 2 penetrate through the plane of the silicon steel sheet, and the paint film is not damaged. Therefore, when a large number of magnetic excitation wires pass through the plane of the silicon steel sheet, the silicon steel sheet in the high-verticality area generates very large eddy current loss, so that the silicon steel sheet generates heat and even turns red to burn out the transformer.

Secondly, the aging of the coil insulator is accelerated by the local overhigh temperature of the coil

In the process of iron core column magnetic derivatization under rated load, under the side derivatization effect, the strength of the whole magnetic excitation wire of the magnetic iron core column is inconsistent, so that the induced electric potentials received by the coil are inconsistent, and the coil is locally overheated (as shown in fig. 11 and 12): the heating point is in the insulating carbonization phenomenon (coil heating carbonization part 42) of the coil 10 from top to bottom in a strip shape, and at this time, a great amount of leakage magnetic is derived to nearby metal bodies, such as the wall of an oil tank, so that the nearby metal bodies generate heat and additional loss is increased until the transformer coil is burnt out.

Thirdly, the production cost is high and the material utilization rate is low. The traditional transformer iron core is limited by conditions so far, and the actual condition of the excitation characteristic of the iron core under rated load cannot be detected, so that the improvement direction of raw materials is misled, and the relation is considered to be existed between the improvement direction and the thickness of the silicon steel sheet, so that a material manufacturer takes the reduction of the thickness of the silicon steel sheet as a main attack target, and the ultrathin silicon steel sheet appears. However, under the excitation characteristic of rated load, the small amount of change caused by the change is basically not compared with the material production cost without price ratio, but rather, adverse consequences such as the increase of electromagnetic noise of the transformer, the serious reduction of the mechanical force of the iron core, the increase of the difficulty coefficient of the iron core production by 2-3 times and the like caused by the over-thin raw material are generated, the rigorous precision requirement is also brought to a special equipment manufacturer, the manufacturing cost of professional equipment is increased by more than 300 percent, and the immeasurable economic resource loss is increased to the global transformer and the electric equipment manufacturing enterprises with the excitation iron core.

In addition, in order to reduce the so-called no-load loss of the conventional transformer core, the conventional manufacturing enterprises try to achieve the purpose by continuously improving the shape of the iron core sheet, or changing the original stacking of several silicon steel sheets into the staggered stacking of single silicon steel sheets, or changing the original direct seam into an oblique seam, the more the sheet shape is changed, and the lower the utilization rate of the raw material is changed. For example, the iron core of the amorphous alloy transformer which is popular in the current market can only be hung on the coil, so that the stability of the amorphous alloy transformer is sharply reduced; when the engine runs at full load, the electromagnetic noise reaches more than 90 decibels and is uncontrollable, and the electromagnetic vibration caused by the electromagnetic noise exceeds more than 200-300 um. Therefore, the improved product is basically directional error, and more sheet types inevitably lead to low material utilization rate, complex structure, difficult assembly and high production cost, thereby further reducing reliability, economic index and advancement (as shown in fig. 7, the upper and lower yoke sheets 6 and 9 and the iron core columns 7, 71 and 72 are respectively composed of different silicon steel sheet shapes 8).

And fourthly, the mechanical force difference of the iron core column is easy to deform, and the designed insulation distance is difficult to ensure.

Traditional transformer excitation iron core especially large capacity iron core, silicon steel sheet all are flat on the closed assembly platform 16 and are folded and form, when flat folding, because the dead weight of silicon steel sheet is comparatively level, when closed assembly platform 16 upset iron core under the exogenic action, the iron core is by flat when lying and rising (as shown in fig. 9), constitutes iron core post 7 (as shown in fig. 8) and often in the upset in-process, receives the dead weight effect and warp, makes the additional loss increase of iron core post and influences the long-term reliable operation of transformer. Not only increases the assembly difficulty, but also ensures that the designed insulation distance cannot be ensured.

After the iron core is formed into a table, sleeving the coil and the iron core, as shown in fig. 10: at the moment, silicon steel sheets of the upper iron yoke 6 of the iron core need to be folded one by one in the industry, so that the labor intensity is extremely high, and no machine can substitute the prior art. Then, the coil 10 is sleeved, the upper iron yoke sheets are inserted one by one after the coil is sleeved, each sheet is carefully aligned, and the silicon steel sheet of the upper iron yoke 6 can be completely inserted, so that the difficulty is conceivable, the improvement of the capacity is limited, the labor efficiency is low, and the industrial development is seriously limited.

Disclosure of Invention

The invention aims to provide a high-efficiency low-energy-consumption transformer which has the advantages of small eddy current loss, difficult aging of a coil insulator, wide material selection range, high utilization rate, low production cost, simple manufacturing process and high reliability.

The technical scheme for realizing the aim is as follows: this kind of high-efficient low energy consumption transformer, including silicon steel sheet, last indisputable yoke, iron core post and coil down, the iron core post is formed by numerous silicon steel sheet in order of sequence pile, and its main points are: a plurality of silicon steel sheets forming the iron core column are divided into a plurality of units, and each unit is composed of a plurality of groups of silicon steel sheets with different widths; all silicon steel sheets are arranged in an emission shape in a centripetal manner.

Preferably, each of the plurality of groups of silicon steel sheets is formed by stacking a plurality of silicon steel sheets having a uniform width.

Further preferably, the lengths of all the silicon steel sheets are uniform.

More preferably, the length and width of the silicon steel sheets constituting the upper and lower iron yokes are all the same.

Has the advantages that: when the transformer is manufactured, all silicon steel sheets of the iron core column are divided into a plurality of units, each unit is composed of a plurality of groups of silicon steel sheets with different widths, all the silicon steel sheets are arranged radially and centripetally, and the length and the width of each group of silicon steel sheets of the plurality of groups of silicon steel sheets are consistent (as shown in figures 19 and 20), and the length and the width of the upper and lower iron yoke silicon steel sheets are consistent, so that the following technical effects are achieved:

firstly, the eddy current loss (load loss) of the iron core is small.

The lamination direction of each silicon steel sheet forming the iron core column is parallel to the magnetic excitation line in the magnetic derivation process, so that the phenomenon that the magnetic excitation line penetrates through the plane of the silicon steel sheet is completely eliminated. Under the no-load state, the load loss of the product is not greatly changed when the product is tested by a traditional short circuit method, and when the product is loaded, because the lamination direction of the silicon steel sheets of the transformer core column is changed, the excitation characteristic of the iron core can be shown under the rated load, the magnetic excitation wire is parallel to the lamination direction in the magnetic derivation process, and the magnetic excitation wire has no chance of penetrating through the plane of the silicon steel sheets, so that the silicon steel sheets parallel to the magnetic excitation wire cannot generate extra eddy current loss, and the extra eddy current loss of the iron core is eliminated.

Secondly, eliminating the phenomenon of over-high local temperature of the coil and slowing down the aging speed of the coil insulator

Because the lamination direction of the improved core limb is parallel to the magnetic excitation line direction in the magnetic derivation process, the core limb magnetic excitation lines are uniformly distributed on the coil under the side derivation effect, the regional eddy current sudden increase condition of the core limb is thoroughly eliminated (as shown in figures 13 and 14), the phenomenon of high local temperature of the core limb coil does not occur, the environmental temperature of the internal structure of the transformer is changed, and the normal, reliable and low-energy-consumption long-term operation of the transformer is ensured.

High material utilization rate, wide material selection range, low production cost

The technology of the invention changes the lamination direction of the iron core column silicon steel sheets and eliminates a large amount of eddy current loss of the iron core silicon steel sheets. The sheet shape is simple, the iron yoke only has one sheet width, the iron core column only has one rectangular sheet shape, the large sheet and the small sheet are split when cutting, the material utilization rate is up to more than 99.5%, the operability is strong, and the resource waste is less. The defects of complicated shape, diversity and low utilization rate of the traditional transformer iron core are overcome. The technical product can be produced by adopting the common silicon steel sheet with the thickness of 0.27-0.35mm, and can meet the load loss requirement of the amorphous alloy. Tests show that under the rated load state, the load loss of the transformer is lower than that of the traditional transformer by more than 30 percent, the harm caused by over-thin raw materials is reduced, the innovation and improvement directions of raw material production enterprises are thoroughly changed, and the social and economic benefits are very obvious.

Fourthly, the iron core column has strong mechanical rigidity and does not deform, and the designed insulation distance can be reliably ensured

Because the transformer iron core mainly comprises the upper iron yoke, the lower iron yoke and the iron core column, when the transformer iron core is assembled, the coil can be sleeved after the iron core column and the lower iron yoke are assembled, the work of disassembling the upper iron yoke sheet is not needed, and the upper iron yoke can be installed after the coil is sleeved, (as shown in figures 15 and 16), the efficiency can be improved by more than 10 times. Because the iron core column silicon steel sheets are stacked in an emission shape, the sheets are mutually supported in 360 degrees, and the rigidity of a single silicon steel sheet in the width direction is extremely high, so that the pressure resistance of the whole iron core column is improved to a great extent. The deformation of the silicon steel sheets is very small because the sheet-wide slits 21 of all the silicon steel sheets are stressed.

The iron core column has strong rigidity and does not deform, so that the designed insulation distance between the iron core and the coil is ensured, the additional loss increase caused by the deformation of the iron core column is eliminated, the transformer is firmer, the mechanical noise generated in the operation process of the transformer is reduced, and the reliability and the timeliness of the operation of the transformer are greatly improved. The results of the comparative tests are as follows:

table 1: transformer comparison table of the application and the prior art

Note: the reduction is calculated as W1 ÷ W2-1 × 100. Table 1 illustrates that the load loss value of the transformer of the present application is significantly reduced compared to the prior art transformer.

In conclusion, the technical product of the invention has the advantages of small iron core eddy current loss (load loss), elimination of the phenomenon of overhigh local temperature of the coil, reduction of the aging speed of the coil insulator, low production cost, high material utilization rate, strong mechanical rigidity of the iron core column without deformation, and reliable guarantee of the designed insulation distance.

The invention will be further described by way of example with reference to the accompanying drawings.

[ description of the drawings ]

Fig. 1 is a schematic view of an outer segment circle lamination structure of a core limb cross section in the prior art.

Fig. 2 is a schematic diagram of a prior art square lamination stack of a core limb cross-section.

Fig. 3 is a schematic view of a rectangular lamination structure of a core limb cross section in the prior art.

Fig. 4 is a schematic view of a three-dimensional rolled lamination structure of a core limb section in the prior art.

Fig. 5 is a schematic view of an involute lamination stack of a core limb section in the prior art.

Fig. 6 is a schematic diagram of distribution of excitation lines in a core limb cross section in the prior art.

Fig. 7 is a schematic diagram of a core structure and sheet shape according to the prior art.

Fig. 8 is a stacked view of a prior art core.

Fig. 9 is a schematic view of the core erection structure of fig. 8 rotated by 90 degrees.

Fig. 10 is a schematic diagram of a sleeving structure of a coil and an iron core in the prior art.

Fig. 11 is a schematic diagram of the prior art coil and core strip heating from top to bottom.

Fig. 12 is a schematic cross-sectional view of fig. 11, showing heat generation in the coil and core limb regions according to the prior art.

Fig. 13 is a schematic cross-sectional view of a core limb of the present invention.

Fig. 14 is a schematic structural view of fig. 13 after the coil is sleeved.

Fig. 15 is a schematic view of an assembly structure of a core and a coil according to the present invention.

Fig. 16 is a left side view of the structure of fig. 15.

Fig. 17 is a schematic view of a stack-up forming structure of a core limb of the present invention.

Fig. 18 is a schematic cross-sectional structure of fig. 17.

Fig. 19 is a schematic plan view of a unit silicon steel sheet of an iron core column according to the present invention.

Fig. 20 is a schematic cross-sectional structure of fig. 19.

Fig. 21 is a schematic view showing a plate-shaped structure of an upper yoke or a lower yoke of a core according to the present invention.

Fig. 22 is a schematic cross-sectional structure of fig. 21.

Fig. 23 is an enlarged schematic view of the structure of fig. 18.

Fig. 24 is a schematic diagram of the internal structure of the transformer after the transformer is completed.

Fig. 25 is a left side view of the schematic of fig. 24.

In the figure: 1. the magnetic excitation wire comprises silicon steel sheets, 2 magnetic excitation wires, 3 magnetic excitation wire diffraction directions, 4 iron core heating carbonization parts, 41 iron core heating carbonization parts, 42 coil heating carbonization parts, 5 magnetic excitation wires parallel to the lamination direction, 6 upper iron yokes, 61 upper iron yokes, 7 iron core columns, 71 iron core columns, 72 iron core columns, 8 silicon steel sheet sheets, 9 lower iron yokes, 91 lower iron yokes, 10 coils, 11 clamping pieces, 12 bases, 13 tightening devices, 14 non-dimensional belts, 15 tightening ropes, 16 stacking platforms, 17 lifting hooks, 18 units, 19 groups, 20 built-in surfaces and 21 sheet wide cuts.

[ detailed description ] embodiments

See fig. 13, 14, 19 and 20. The structure of this high-efficient low energy consumption transformer of technique includes yoke 6, lower yoke 9, silicon steel sheet 1, iron core post 7 and coil 10, and iron core post 7 is formed by piling up in proper order numerous silicon steel sheet 1, and its main points are: the silicon steel sheets 1 forming the iron core column 7 are divided into a plurality of units 18, and each unit 18 is composed of a plurality of groups 19 of silicon steel sheets with different widths; all the silicon steel sheets 1 are arranged in an emission shape and centripetal manner. Each group 19 of the multiple groups of silicon steel sheets is formed by stacking a plurality of silicon steel sheets 1 with the same width; the lengths of all the silicon steel sheets 1 are consistent; the lengths and the widths of the silicon steel sheets 1 of the upper iron yoke 6 and the lower iron yoke 9 are consistent.

In the specific manufacturing process, the core column 7 is composed of a plurality of units 18 according to the diameter of the core column, each unit 18 is composed of a plurality of groups 19 of silicon steel sheets 1 with different widths and consistent lengths, and each group 19 is composed of a plurality of silicon steel sheets 1 with consistent widths and lengths. As can be seen from fig. 20, the unit 18 is composed of five groups 19 of silicon steel sheets 1, the number of groups being increased or decreased by the diameter of the core limb 7.

See fig. 21 and 22. The upper iron yoke 6 and the lower iron yoke 9 of the invention are formed by the same rectangular silicon steel sheet.

See fig. 17, 18 and 23. The stacking and forming process of the iron core column 7 is shown, and it can be seen that the stress point of each silicon steel sheet is on the sheet wide notch 21, so that the silicon steel sheets cannot be deformed, the sheets and the sheets are supported by each other at 360 degrees, and the whole iron core column has high mechanical strength and strong pressure resistance.

See fig. 24, 25. The internal structure of the transformer after the platform forming is shown schematically.

The above-mentioned embodiments are merely illustrative of the essence of the present invention, and should not be considered as specific limitations of the structure of the present invention, and any simple modifications made according to the embodiments should be included in the protection scope of the present invention.