阅读说明：本技术 取能传感器的合金整环的制造工艺、合金整环及取能电源 (Manufacturing process of alloy whole ring of energy-taking sensor, alloy whole ring and energy-taking power supply ) 是由 高昇 任涛 于 2020-06-02 设计创作，主要内容包括：本发明公开了取能传感器的合金整环的制造工艺、合金整环及取能电源,涉及传感器技术领域,用以优化取电方式,优化电源解决方案。制造工艺包括：将基础带材缠绕成合金整环；退火；固化胶水中真空浸泡；将合金整环以中心线为基准切割成两个半环。合金整环采用上述制造工艺所制造。取能电源包括：取能传感器和储能模块。本发明可在线路上取电,密封于防水外壳中仍可正常取电,合金整环的取电效率更加稳定。(The invention discloses a manufacturing process of an alloy whole ring of an energy-taking sensor, the alloy whole ring and an energy-taking power supply, relates to the technical field of sensors, and aims to optimize an electricity-taking mode and a power supply solution. The manufacturing process comprises the following steps: winding the base strip into an alloy whole ring; annealing; vacuum soaking in curing glue; and cutting the alloy whole ring into two semi-rings by taking the central line as a reference. The alloy whole ring is manufactured by the manufacturing process. The energy-taking power supply comprises: the energy acquisition sensor and the energy storage module. The invention can get electricity on the circuit, can get electricity normally when sealed in the waterproof shell, and has more stable electricity getting efficiency of the alloy whole ring.)

1. A manufacturing process of an alloy whole ring of an energy-taking sensor is characterized by comprising the following steps:

tape coiling and forming: winding the base strip into an alloy whole ring;

and (3) annealing: annealing the alloy whole ring;

and (3) curing: putting the alloy whole ring into curing glue for vacuum soaking;

cutting the whole ring: cutting the alloy whole ring into two semi-rings by taking the central line as a reference;

the product area of the whole alloy ring is

Wherein A is_eDenotes the cross-sectional area of the core, A_wDenotes the window area of the core, P_oRepresents output power,. DELTA.B represents the amount of change in magnetic flux density, f_TRepresenting the transformer operating frequency and K the coefficient.

2. The process for manufacturing an alloy full ring of an energy-extracting sensor as claimed in claim 1, wherein between the step of solidifying and the step of cutting the full ring, the process further comprises: spraying insulation: and spraying resin paint on the surface of the solidified alloy whole ring.

3. The process for manufacturing an alloy full ring for an energy sensor as claimed in claim 1, further comprising, after the step of cutting the full ring: grinding the surface: and grinding the cut sections of the two semi-rings.

4. The process for manufacturing the alloy whole ring of the energy-taking sensor according to claim 1, wherein in the annealing step, the annealing time is 50 hours to 60 hours.

5. The process for manufacturing the alloy whole ring of the energy-taking sensor as claimed in claim 1, wherein in the solidifying step, the vacuum soaking time is 5 to 10 hours.

6. The process for manufacturing the alloy whole ring of the energy-taking sensor as claimed in claim 1, wherein the base strip is made of 1J85 type iron-nickel alloy material.

7. An alloy full ring manufactured by the manufacturing process of the alloy full ring of the energy extraction sensor according to any one of claims 1 to 6, comprising: the base strip is wound into an alloy whole ring, the surface of the alloy whole ring is provided with a solidified glue layer, and the alloy whole ring is cut into two half rings by taking the central line as a reference.

8. An energy extraction power supply, comprising:

the energy-taking sensor obtained by winding a coil by adopting the alloy whole ring manufactured by the manufacturing process of the alloy whole ring of the energy-taking sensor as claimed in any one of claims 1 to 6, and used for taking energy out of a line in an electromagnetic coupling mode and directly supplying power;

and the energy storage module is used for storing part of energy taken out from the energy taking sensor and supplying power for standby.

9. The energy-harvesting power supply of claim 8, wherein the energy storage module is a super capacitor.

10. The energy-harvesting power supply of claim 8, further comprising: a waterproof housing; and placing the energy taking sensor and the energy storage module in the waterproof shell.

Technical Field

The invention relates to the technical field of sensors, in particular to a manufacturing process of an alloy whole ring of an energy-taking sensor, the alloy whole ring and an energy-taking power supply.

Background

The existing electricity taking device takes a solar cell panel as a main power supply solution, the solar cell panel is exposed in the air for a long time and is seriously influenced by the environment, the service life of the solar cell panel can be influenced by factors such as dust, water mist and the like in the air, the electricity taking performance is linearly reduced along with the continuous increase of the service time, the solar cell panel cannot be used for a long time, the solar cell panel is seriously influenced by the weather, the charging efficiency is extremely low in rainy days, the power supply capacity of the solar cell panel is greatly influenced, and the operation of the whole system can be influenced.

Disclosure of Invention

The invention provides a manufacturing process of an alloy whole ring of an energy-taking sensor, the alloy whole ring and an energy-taking power supply, which are used for optimizing an electricity-taking mode and optimizing a power supply solution.

In a first aspect, a process for manufacturing an alloy full ring of an energy sensor according to an embodiment of the present invention includes the following steps: tape coiling and forming: winding the base strip into an alloy whole ring; and (3) annealing: annealing the alloy whole ring; and (3) curing: putting the alloy whole ring into curing glue for vacuum soaking; cutting the whole ring: cutting the alloy whole ring into two semi-rings by taking the central line as a reference; the product area of the whole alloy ring isWherein A is_eDenotes the cross-sectional area of the core, A_wDenotes the window area of the core, P_oRepresents output power,. DELTA.B represents the amount of change in magnetic flux density, f_TRepresenting the transformer operating frequency and K the coefficient.

Preferably, the manufacturing process of the alloy whole ring of the energy sensor according to another embodiment further includes, between the solidifying step and the cutting step: spraying insulation: spraying resin paint on the surface of the solidified alloy whole ring; and, after the step of cutting the whole ring, further comprising: grinding the surface: and grinding the cut sections of the two semi-rings.

Preferably, in the annealing step, the annealing time is 50 to 60 hours.

Preferably, in the curing step, the vacuum soaking time is 5 to 10 hours.

Preferably, the base strip is made of 1J85 type iron-nickel alloy material.

In a second aspect, an alloy full ring according to an embodiment of the present invention is manufactured by the above manufacturing process of an alloy full ring for an energy sensor, including: the base strip is wound into an alloy whole ring, the surface of the alloy whole ring is provided with a solidified glue layer, and the alloy whole ring is cut into two semi-rings by taking the central line as a reference.

In a third aspect, an energy-extracting power supply according to an embodiment of the present invention includes: the alloy whole ring manufactured by adopting the manufacturing process of the alloy whole ring of the energy-taking sensor is used for taking out energy from a circuit in an electromagnetic coupling mode and directly supplying power after being wound by a coil; and the energy storage module is used for storing part of energy taken out from the energy taking sensor and supplying power for standby.

Preferably, the energy storage module is a super capacitor.

Preferably, the energy acquisition device further comprises a waterproof shell, and the energy acquisition sensor and the energy storage module are arranged inside the waterproof shell.

The manufacturing process of the alloy whole ring of the energy-taking sensor, the alloy whole ring and the energy-taking power supply can take electricity on a circuit, do not need to be exposed in an open-air environment like a solar panel, can be sealed in a waterproof shell, and can still take electricity normally, so that the service life of a device is prolonged, the material taking, the shape and the parameters of the alloy whole ring are designed, deduced and calculated, are matched with the alloy whole ring in the manufacturing process flow, and the electricity-taking efficiency is more stable compared with the electricity-taking efficiency of a solar panel power supply solution scheme.

Drawings

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention and not to limit the invention. In the drawings:

FIG. 1 is a flow chart of a manufacturing process of example 1 of the present invention;

FIG. 2 is a flow chart of a manufacturing process of example 2 of the present invention;

FIG. 3 is a schematic view of an alloy full ring structure according to example 3 of the present invention;

FIG. 4 is a schematic structural view of an alloy full ring according to example 4 of the present invention;

fig. 5 is a schematic diagram of an energy-obtaining power supply structure in embodiment 5 of the present invention.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments.

Embodiment 1, because the current mode of getting electricity adopts solar cell panel as main power supply solution more, solar panel must expose in the air for a long time, it is comparatively serious to receive environmental impression, factors such as dust in the air and water smoke all can influence solar panel's life-span, along with the live time constantly increases, get the electric property straight line decline, can't use for a long time, and solar panel receives weather effect comparatively seriously, overcast and rainy day gas charge efficiency is extremely low, consequently, current solar panel power supply solution gets the electric efficiency unstability, and life is limited, need a new mode of getting electricity to replace solar panel and get the electric scheme. The manufacturing process of the alloy whole ring of the energy-taking sensor in the embodiment is shown in fig. 1, and comprises the following main steps:

s11, tape forming: the base strip is wound into an alloy full ring.

In the embodiment, the principle of mutual electromagnetic inductance is used as a power supply solution, but the material of the base strip material, the shape of the alloy whole ring and the derivation and calculation of the parameters of the alloy whole ring are required.

In the embodiment, the alloy whole ring is made of 1J85 type iron-nickel alloy, the electricity taking efficiency of the 1J85 iron-nickel alloy after subsequent process treatment can reach more than 80% of that of the whole ring, and the alloy whole ring has excellent corrosion resistance; stable power supply can be continuously obtained on a low-load line.

The alloy whole ring manufactured by the process of the embodiment selects the circular energy-taking magnetic core as the shape of the alloy whole ring.

In addition, as described above, the line current is unstable, and the parameters of the alloy loop need to be derived and calculated.

In this embodiment, the product area of the alloy whole ring is derived and the formula is used

Wherein A is_eDenotes the cross-sectional area of the core, A_wDenotes the window area of the core, P_oRepresents the output power (W), Δ B represents the flux density variation (T), f_TRepresenting the transformer operating frequency (Hz), and K represents a coefficient, which is 0.014 (forward converter, push-pull center tap) and 0.017 (full bridge, half bridge).

In a specific implementation, the loss of most magnetic materials is low at the working frequency of 50KHz, and the saturation of the magnetic core material limits the selection of magnetic flux density. The saturation magnetic flux density of ferrite is about 0.3T at 100 degrees, and when the magnetic flux density is more than 0.2T, the magnetic field intensity is obviously increased, the magnetizing current is rapidly increased, and the coil loss is increased. To avoid saturation of the core during transients, the flux density swing is chosen to be 0.16T. And if the frequency exceeds 50KHz, selecting the magnetic flux density swing amplitude delta B according to 100-200 mW/cm3 on the magnetic core loss curve according to the working frequency. The output power should be multiplied by a factor deltab/0.16.

The design requires that the output power reaches 9W, the maximum variation of the magnetic flux density is 0.3T, and the product area of the required alloy whole ring is as follows under the assumption that the circuit works at the frequency of 50 Hz:

selecting high magnetic permeability, high frequency and low loss material, i.e. 1J85 type Fe-Ni alloy

AP＝A_eA_w＝0.388×1.49＝0.57812cm⁴。

After the materials, the shapes and the parameters are determined, flattening the 1J85 type iron-nickel alloy strip with the thickness of 0.1mm, and then entering a winding tape winding machine to wind the basic strip into an alloy integral ring.

S12, annealing: and annealing the alloy whole ring.

Specifically, the alloy whole ring wound with the strip is placed into an annealing furnace for annealing, and the annealing time is preferably 50 hours to 60 hours.

S13, curing: and putting the alloy whole ring into curing glue for vacuum soaking.

Specifically, the alloy whole ring after annealing and cooling is placed into curing glue for soaking, the soaking environment is vacuum soaking, and the vacuum soaking time is preferably 5 to 10 hours.

S14, cutting the whole ring: and cutting the alloy whole ring into two semi-rings by taking the central line as a reference.

Specifically, the alloy whole ring is cut into two semi-rings by taking the central line as a reference, and the cutting section cannot have the phenomena of layer formation, cracking and the like in the cutting process. The purpose of cutting into two half-rings is to facilitate mounting on the line.

The alloy whole ring manufactured by the manufacturing process of the alloy whole ring of the energy-obtaining sensor has the basis of obtaining electricity on a circuit, is not exposed to the outdoor environment like a solar panel, can be sealed in a waterproof shell, still can normally obtain electricity, and prolongs the service life of a device.

Embodiment 2, because the current mode of getting electricity adopts solar cell panel as main power supply solution more, solar panel must expose in the air for a long time, it is comparatively serious to receive environmental impression, factors such as dust in the air and water smoke all can influence solar panel's life-span, along with the live time constantly increases, get the electric property straight line decline, can't use for a long time, and solar panel receives weather effect comparatively seriously, overcast and rainy day gas charge efficiency is extremely low, consequently, current solar panel power supply solution gets the electric efficiency unstability, and life is limited, need a new mode of getting electricity to replace solar panel and get the electric scheme. The manufacturing process of the alloy whole ring of the energy-taking sensor in the embodiment is shown in fig. 2, and includes the following main steps:

s21, tape forming: the base strip is wound into an alloy full ring.

In the embodiment, the principle of mutual electromagnetic inductance is used as a power supply solution, but the material of the base strip material, the shape of the alloy whole ring and the derivation and calculation of the parameters of the alloy whole ring are required.

In the embodiment, the alloy whole ring is made of 1J85 type iron-nickel alloy, the electricity taking efficiency of the 1J85 iron-nickel alloy after subsequent process treatment can reach more than 80% of that of the whole ring, and the alloy whole ring has excellent corrosion resistance; stable power supply can be continuously obtained on a low-load line.

The alloy whole ring manufactured by the process of the embodiment selects the circular energy-taking magnetic core as the shape of the alloy whole ring.

In addition, as described above, the line current is unstable, and the parameters of the alloy loop need to be derived and calculated.

In this embodiment, the product area of the alloy whole ring is derived and the formula is used

Wherein A is_eDenotes the cross-sectional area of the core, A_wDenotes the window area of the core, P_oRepresents the output power (W), Δ B represents the flux density variation (T), f_TRepresenting the transformer operating frequency (Hz), and K represents a coefficient, which is 0.014 (forward converter, push-pull center tap) and 0.017 (full bridge, half bridge).

In a specific implementation, the loss of most magnetic materials is low at the working frequency of 50KHz, and the saturation of the magnetic core material limits the selection of magnetic flux density. The saturation magnetic flux density of ferrite is about 0.3T at 100 degrees, and when the magnetic flux density is more than 0.2T, the magnetic field intensity is obviously increased, the magnetizing current is rapidly increased, and the coil loss is increased. To avoid saturation of the core during transients, the flux density swing is chosen to be 0.16T. And if the frequency exceeds 50KHz, selecting the magnetic flux density swing amplitude delta B according to 100-200 mW/cm3 on the magnetic core loss curve according to the working frequency. The output power should be multiplied by a factor deltab/0.16.

The design requires that the output power reaches 9W, the maximum variation of the magnetic flux density is 0.3T, and the product area of the required alloy whole ring is as follows under the assumption that the circuit works at the frequency of 50 Hz:

selecting high magnetic permeability, high frequency and low loss material, i.e. 1J85 type Fe-Ni alloy

AP＝A_eA_w＝0.388×1.49＝0.57812cm⁴。

After the materials, the shapes and the parameters are determined, flattening the 1J85 type iron-nickel alloy strip with the thickness of 0.1mm, and then entering a winding tape winding machine to wind the basic strip into an alloy integral ring.

S22, annealing: and annealing the alloy whole ring.

Specifically, the alloy whole ring wound with the strip is placed into an annealing furnace for annealing, and the annealing time is preferably 50 hours to 60 hours.

S23, curing: and putting the alloy whole ring into curing glue for vacuum soaking.

Specifically, the alloy whole ring after annealing and cooling is placed into curing glue for soaking, the soaking environment is vacuum soaking, and the vacuum soaking time is preferably 5 to 10 hours.

S24, spraying insulation: and spraying resin paint on the surface of the solidified alloy whole ring.

Specifically, resin paint is sprayed on the surface of the solidified alloy whole ring, and the spraying of the insulating resin mainly plays a role in isolating the iron-nickel alloy from the outside and playing a role in secondary solidification. The resin spraying includes dry spraying and wet spraying, and the wet spraying is adopted in the embodiment.

S25, cutting the whole ring: and cutting the alloy whole ring into two semi-rings by taking the central line as a reference.

Specifically, the alloy whole ring is cut into two semi-rings by taking the central line as a reference, and the cutting section cannot have the phenomena of layer formation, cracking and the like in the cutting process. The purpose of cutting into two half-rings is to facilitate mounting on the line.

S26, grinding the surface: and grinding the sections of the two cut semi-rings.

Specifically, the cut sections of the two iron-nickel alloy semi-rings are ground, so that a better energy taking effect is achieved.

And S27, detecting the ground alloy whole ring.

Specifically, the ground finished product is subjected to high-low temperature, salt spray, flapping and drop tests respectively, and leaves the factory after meeting the test standards.

The alloy whole ring manufactured by the manufacturing process of the alloy whole ring of the energy-obtaining sensor has the basis of obtaining electricity on a circuit, is not exposed to the outdoor environment like a solar panel, can be sealed in a waterproof shell, still can normally obtain electricity, and prolongs the service life of a device.

Embodiment 3 and the alloy whole ring of this embodiment are manufactured by the alloy whole ring manufacturing process of the energy sensor of embodiment 1, and as shown in fig. 3, the alloy whole ring 31 is formed by winding a base strip, the surface of the alloy whole ring 31 has a solidified glue layer 32, and the alloy whole ring 31 is cut into two half rings based on a center line, which is not described in detail.

Embodiment 4 and the alloy whole ring of this embodiment are manufactured by using the alloy whole ring manufacturing process of the energy sensor of embodiment 2, and as shown in fig. 4, the alloy whole ring 41 is wound by a base strip, a cured glue layer 42 is provided on the surface of the alloy whole ring 41, a resin coating layer 43 is sprayed on the outer surface of the cured glue layer 42, and the alloy whole ring 41 is cut into two half rings based on a center line, which is not described in detail.

Embodiment 5, the energy obtaining power supply of this embodiment, as shown in fig. 5, includes: the energy acquisition sensor 51, the energy storage module 52 and the waterproof shell 53.

The alloy whole ring of the energy sensor 51 is manufactured by the manufacturing process of the embodiment 1 or 2, and is wound with a coil to obtain the energy sensor 51, which is used for taking out energy from a line in an electromagnetic coupling mode and directly supplying power.

In the concrete implementation, the actual area of the open-loop magnetic core area is larger than the area of the magnetic core required by a theoretical value, so that the design requirement can be met, and the calculation formula of the inductance coefficient is as follows:

the number of coil turns is calculated as:

inductance coefficient A of 1J85 type iron-nickel alloy material coefficient_L105nH/N2, then:

for reasons of wire diameter and space, wires with a cross-sectional area parameter of 10 x 10(mm) are chosen in a specific implementation. Typical test conditions were obtained after several tests: the magnetic core material is iron-nickel alloy, the outer diameter of the paint is 76mm, the width and the thickness of the paint are 11mm, the number of turns of the coil is 400 turns, the wire diameter of the coil is 0.44mm, and the normal temperature T is 25 ℃.

The energy storage module 52, which is a super capacitor in this embodiment, is used to store part of the energy taken from the energy sensor 51 and serves as a backup power supply.

And the waterproof shell 53 is used for placing the energy taking sensor 51 and the energy storage module 52 inside. In concrete realization, the material of aluminum alloy armour is selected to waterproof shell 53, and this material has outstanding waterproof anticorrosive effect, has characteristics such as the quality is light, hard, antistatic, anti-electromagnetic interference simultaneously, can effectually reach the demand that equipment used in outdoor power consumption environment for a long time. Because the energy-taking sensor 51 takes energy by means of loop-fastening on the circuit to sense the circuit current, the equipment needs to be designed into a hollow mode for the lead to pass through, and the installation mode is to use a soft hoop for fixing.

The energy-taking power supply of the embodiment can take electricity on a circuit, and does not need to be exposed to the outdoor environment like a solar panel, can be sealed in a waterproof shell, and still can normally take electricity, so that the service life of a device is prolonged. And this embodiment has still set up super capacitor as energy storage module, charges when getting can the sensor can be sufficient to get can, as reserve power supply mode when getting can the sensor can not be sufficient to get, has ensured the stability of power supply more.

It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.