Distribution transformers

Abstract: A distribution transformer has a wound magnetic core (50) of overall circular shape and rectangular cross-section with between two and four overall rectangular shape electric coils (20, 30) extending through the core window. The coils (20, 30) are pre-formed and assembled so that their parts (20A, 30A) which meet form a circular section solid cylinder. A mandrel (40) is then located around this cylinder (20A, 30A). Amorphous steel strip is first wound on to another mandrel, annealed, and then transferred from the other mandrel on to the mandrel around the coils.

Description: This invention relates to electrical power distribution transformers. In particular the invention relates to methods of making such distribution transformers of the type which include a core and coil assembly having a wound magnetic core with a central window and one or more electric coils which extend through said core window, and to the transformers so made. Two known methods of making a transformer core and coil assembly of the above-defined type, and in which the core is of overall rectangular shape, will now be described. In the first such known method the wound core is made by winding magnetic steel strip of single width into a circular roll, and in winding each turn it is cut at approximately the same point. The circular roll is then pressed into an overall rectangular shape core having distributed gaps through one side of the rectangle where the turns were cut, and it is then annealed to fix the rectangular shape. The cut core turns are then opened up and bent out to form a U-shape, a pre-formed rectangular cylindrical coil is assembled on each of the two legs of the U-shape, and the cut core turns are then closed to re-form the rectangular core shape and are jointed. However well the cuts are jointed they will add significantly to the power loss of the core. Also with this method, the machinery for cutting the magnetic steel strip involves significant cost. Furthermore the present and expected future trend is to use progressively thinner magnetic steel strip which has inherently lower power loss, but thinner strip is more difficult to handle in processes which involve cutting. Another disadvantage of this method is that the equipment and process involved in annealing the core contributes significantly to the cost of manufacturing the transformer. In the second known method of making a rectangular shape wound core transformer, magnetic steel strip of varying width is wound continuously without cuts on to a rectangular mandrel to form an overall rectangular shape core with an approximately circular cross-section. The core is then annealed to fix the rectangular shape. Split mandrels are then fitted over two legs of the core and a circular cylindrical coil is wound on to each mandrel. This second method avoids the manufacturing and power loss disadvantages associated with cutting in the above-described first method. However there is still the cost disadvantage of annealing the core. There are two further disadvantages of this second method. Firstly the only approximately circular cross-section of the core within the circular coils gives a significant reduction in space factor and hence higher power loss. Secondly, for larger size coils there is an increased level of difficulty in winding the coils leading to a practical upper limit of approximately 50KVA rated power for transformers made by this method, which does not cover the full rated power range required for distribution transformers. Patent Abstracts of Japan Vol. 4 Number 175 (E-36) (657) December 3, 1980 discloses a method of making a circular shape wound core transformer, in which method single width non-amorphous continuous steel strip is wound around adjoining limbs of two pre-formed rectangular shape coils. This avoids the power loss associated with a cut core, but the rectangular section of the coils within the circular window of the core results in a low space factor and associated high power loss. WO-A-83/02194 discloses a method of manufacturing a transformer comprising the steps of forming electric windings around at least two electrically insulating annular coil forms; attaching the coil forms to each other by adjacent edges of said forms; forming a suitably shaped thin strip of magnetic material by a splitting process; and then winding around a section of the coil forms at a location in which the coil forms are attached to each other said thin strip of magnetic material while using the coil forms as a guide for winding such that said thin strip is wound through a centre of said annular coil forms. The disclosure of this document shows all the electric coils to be of overall circular shape. Each magnetic core winding is discontinuous in that it is formed of a plurality of separate strips, these separate strips have different widths and most of these separate strips have a varying width. The cores have an overall circular shape but with a non-rectangular cross-section so that the cores substantially fill the circular windows of the coils. Substantially filling the coil windows gives a good space factor with associated low power loss. However, there are disadvantages manufacturing costs of providing the different width strips and power loss disadvantages in having a discontinuous wound core. Although the detailed examples relate to the use of non-amorphous magnetic material for the core, it is mentioned that the method of the disclosure may use amorphous magnetic material. Recently transformer cores have become known which are made with amorphous steel strip. This material has much lower power loss than non-amorphous steel, but this advantage is partially offset by the higher intrinsic material cost. Also, amorphous steel has only been available with a strip width up to approximately 200mm, 213mm being the highest strip width of which we are aware, which limits the size of wound cores using a single strip width and hence the rated power of transformers using such cores so that they do not cover the full rated power range required for distribution transformers. In IEEE Transactions on Power and Apparatus Systems, Vol.PAS-103, No.11, November 1984, pages 3365 to 3372 there is published a paper by E.L. Boyd and J.D. Borst entitled "Design concepts for an amorphous metal distribution transformer". In the summary at the end of this paper it is stated that "The unique characteristics of amorphous metals present significant challenges to the transformer designer and will likely result in a radically different core-coil assembly. This paper has defined a broad range of theoretical core-coil configurations and refined these to a feasible set of solutions through qualitative analysis of amorphous metal characteristics, transformer design requirements, and transformer assembly techniques." One of the feasible theoretical core-coil configurations discussed as worth future consideration for use with amorphous metal shows an overall circular shape uncut core with rectangular cross-section and two rectangular coils extending through the window of the core (configuration IIB in Figure 3). These two rectangular coils are shown each to have a substantially semi-circular cross-section where they meet, so that the core window is substantially filled by the two coils. This configuration would avoid power loss associated with a discontinuous core, and provide a low space factor power loss. Considering the Boyd and Borst paper further, various core-coil assembly options are discussed, and one option identified for the above-mentioned configuration IIB is to wind amorphous metal on to previously wound coils by rotating the core. However, it is stated in relation to the uncut circular core, rectangular coil configuration IIB on page 3371, right-hand column, that "Because the cores are not annealed after forming, the no load loss --- would be among the highest of the configuration possibilities". Indeed, it is known to anneal amorphous steel wound magnetic cores in a saturating magnetic field in order to induce alignment of the domain structure in the preferred magnetic direction around the transformer core, and this has been done prior to assembly ofthe coils on to the core. If amorphous steel is not annealed under magnetic induction, its inherent power loss is higher than that of conventional steel. According to the present invention there is provided a method of making an electrical power distribution transformer which includes a core and coil assembly having a wound magnetic core with a central window and electric coils which extend through said core window, the method including the steps of: (i) individually pre-forming each of a number of overall rectangular shape said electric coils so that said coil has a sector of a circle cross-section at least where it will pass through the core window, (ii) assembling the pre-formed coils together so that their circle sector cross-sectioned parts combine to form a circular section solid cylinder where they meet, and (iii) rotating a core wound from single width amorphous steel strip on to said circular section solid cylinder to form thereon an uncut said wound magnetic core having overall circular shape and rectangular cross-section, with said core window substantially filled by said coils, the method being characterised in that in step (i) said number of coils is in the range between two and four coils, and each coil is pre-formed by winding electrical conductors on a respective support which provides a groove having at least in part the shape of said sector of a circle, in that after step (ii) and before step (iii) the method includes the further steps of (iv) locating a hollow first circular cylindrical mandrel around said circular section solid cylinder, (v) rotating at least one second circular cylindrical mandrel having the same external diameter as said first mandrel to wind thereon a roll of continuous single or multiple thickness single width amorphous steel strip, and (vi) annealing the or each said roll of amorphous-steel strip under magnetic saturation, and in that step (iii) includes rotating the first and second mandrels to transfer the annealed amorphous steel strip as a single roll or up to four stacked co-axial rolls on to the first mandrel to form thereon said uncut wound magnetic core. Transferring the annealed amorphous steel strip between the two mandrels in the method according to the invention will stress the strip and introduce some power loss, but we believe this will be sufficiently small so that a worthwhile advantage is achieved in having amorphous steel in this uncut circular wound core configuration. Thus the invention enables the low weight, low loss advantage of the circular wound core configuration compared with a rectangular core configuration for a transformer of the same rated power to be extended to the use of lower loss amorphous steel. In a method according to the invention as defined above each said coil may be pre-formed by winding said electrical conductors on a respective said support comprising a former made up of sections, after which the former sections are separated for removal of the coil. In a method according to the invention as defined above, respectively said first mandrel may be of electrically insulating material. In a method according to the invention as defined above, the steel strip forming the wound magnetic core is preferably of single thickness for ease of manufacture. Also in a method according to the invention as defined above, the wound magnetic core will preferably consist of a single roll of steel strip for ease of manufacture. Most conveniently in a method according to the invention as defined above, two said electric coils extend through said core window in the transformer, each coil having a semi-circular cross-section where it passes through the core-window. One reason is that it may be desirable to impregnate the coils with resin to enable them to withstand short-circuit forces and this will be done for each coil before the coils are assembled together. The support structure of such as assembly will be more difficult to arrange if there are more than two resin impregnated coils. Another reason is that, in the case where the support on which each such coil is wound comprises sectioned former, then this former need only have two sections. If there are more than two coils, then for each coil the former will need to have more than two sections which will provide a groove having, for where the coil will pass through the core, the shape of a sector of a circle less than a semi-circle and will enable these sections to be removed from the coil after that coil has been wound. In a method according to the invention as defined above the transformer made by the method may be single phase with all the coils extending through only one core. If multi-phase transformation is required using a transformer made by a method in accordance with the invention it will be possible to provide a suitable number of discrete side-by-side single-phase transformer configurations. Alternatively, for a three-phase transformer, we consider it possible to make by a method according to the invention a configuration with three said overall circular, rectangular cross-section, wound cores and four said rectangular coils, with each core window having two of said coils passing through it and these two coils each having a semi-circular cross-section where they pass through this core window. Examples of methods of making transformers in accordance with the invention will now be described with reference to the accompanying drawings, in which Figure 1 shows a perspective view of a sectioned former on which a coil for a transformer is to be wound, Figure 2 shows a part elevation of the former of Figure 1, on enlarged scale, with a coil wound thereon, Figure 3 shows the coil-core configuration of a transformer with two pre-formed coils assembled together, a mandrel around a circular cylinder formed by the coils where they meet, and an incomplete magnetic core formed by winding steel strip on the mandrel, and Figure 4 shows the coil-core configuration of a three-phase transformer having three wound cores and four rectangular coils. Referring now to the drawings, Figure 1 shows a rectangular former made up of two sections 1A, 1B of any suitable material with their edges shaped so that when held together (and meeting where shown by the dotted line) they provide a semi-circular shape groove 1C. Figure 2 shows the configuration of an electrical coil for a transformer wound in the groove 1C of the former 1A, 1B. The whole groove is first lined with an insulation layer 21 and a flat insulation layer 22 is then positioned at the innermost part of the groove. Electrical conductor is then wound into the groove to form an inner primary winding 23 for the transformer which may have an input primary voltage of 33KV. A further flat insulation layer 24 is placed on the primary winding 23, and further electrical conductor is then wound into the groove 1C to fill the groove and form an outer secondary winding 25 for the transformer which may have an output secondary voltage of 400V. The windings 23 and 25, with the insulation layers 21, 22, 24 provide a pre-formed coil 20 from which the former sections 1A and 1B are then removed. The shape of the pre-formed coil 20 can then be consolidated by taping. The preformed coil 20 is then assembled together with a similar pre-formed coil 30 as shown in Figure 3 so that where they meet their semi-circular cross-sectioned parts 20A, 30A combine to form a circular section solid cylinder. A hollow circular mandrel 40 of electrically insulating material, for example epoxy resin, is then formed around the circular cylinder 20A, 30A. If non-amorphous conventional grain orientated electrical steel were to be used to form a magnetic core, the mandrel 40 would then be rotated to wind thereon a roll of continuous such electrical steel strip to form an uncut, unannealed, wound magnetic core 50 which fills the space within the coils 20, 30. For each of illustration only an inner part of the core is shown in Figure 3. The mandrel 40 could be rotated for example by means of gear teeth provided at one end, or by being belt driven at one end, or by a wheel contacting the steel strip. The mandrel 40 would be left to remain in the finished transformer. The mandrel 40 located around the coil cylinder 20A, 30A could alternatively be of metal, preferably non-magnetic, with electrical insulation provided between the mandrel and the coil cylinder. There would thus be provided, as shown in Figure 3, a core-coil configuration having a wound magnetic core 50 with a central window, the core being of overall circular shape and rectangular cross-section formed of non-amorphous steel strip having a single width and two electric coils which are of overall rectangular shape and extend through the core window with the coil cross-sections substantially filling the core window. The primary windings of the two coils 20, 30 may be connected in series with the secondary windings of the two coils connected in parallel to form a single-phase power distribution transformer. The width of the non-amorphous steel strip from which the core 50 could be wound could be in the range 250mm to 1m and of single thickness, although multiple thickness strip could be used. We consider it would be difficult to handle and uneconomic to wind a strip having a width greater than 1m. This strip width would enable transformers to be made having a power rating in the range 10KVA to 2000KVA. A core having this same axial length in the range of 250mm to 1m could be made up to four stacked coaxial rolls, for example two rolls each having a strip width of 500mm. A modification of the method of manufacture described above enables amorphous steel, which is presently available in smaller strip widths of up to approximately 200mm, to be used in accordance with the present invention to provide the same configuration of an uncut circular core wound on pre-formed rectangular coils thus further extending the low loss advantage of this configuration compared with the use of non-amorphous steel. In this modified method the mandrel 40 is located on the circular cylinder 20A, 30A of the pre-formed coils 20, 30 as before. A roll of amorphous steel strip is wound on another mandrel having the same external diameter as the mandrel 40, and this roll of amorphous steel strip is then annealed under magnetic saturation. The mandrel 40 and the other mandrel are then rotated to transfer the annealed amorphous steel strip on to the mandrel 40. It is essential that the two coils 20, 30 have a semi-circular cross-section at least in their legs where they will pass through the core window. A possible alternative to all four legs of each coil 20, 30 having a semi-circular cross-section would be for the leg opposite the core window to be of rectangular section with the two linking legs providing a transformation from semi-circular to rectangular section. As discussed in the introductory portion of this patent specification it is most convenient to have two coils 20, 30 extending through the core 50. More than two coils can be provided, each pre-formed on a former having more than two sections. Each such former will provide a groove having, for where the coil will pass through the core, the shape of a sector of a circle less than a semi-circle such that when the coils are assembled together these circle sector cross-sectioned parts will combine to form a circular section solid cylinder where they meet. It will be difficult to provide a former having the number of sections required for a coil which will be one of a set of more than four coils assembled together to extend through the core window. Partly for this reason and also because, as mentioned in the introductory portion of this patent specification, it may be desirable to impregnate the coils with resin before they are assembled together, we consider the assembly of four coils together to be a practicable upper limit. The former sections 1A, 1B which are held together constitute a support which provides the groove 1C in which the coil conductors are wound. These former sections must be separated for removal of the coil. However, instead of providing former sections which are completely removed after winding the coil, it may be possible to provide a sectioned former assembly which is expanded to separate the sections for removal of the coil while still holding these sections together. A modulated insulating frame may be provided which is fitted in the sectioned former before winding the coil conductors, and this insulating frame may remain as part of the consolidated coil after its removal from the former. It may be possible that such an insulating frame can itself be the support providing the groove for winding the coil, obviating the need for a sectioned former. As discussed in the introductory portion of this patent specification, if multi-phase transformation is required it will be possible to provide a number of discrete side-by-side single-phase transformer configurations. Figure 4 shows an alternative coil-core configuration for a three-phase transformer. There are three overall circular, rectangular cross-section, wound cores 50, 51, 52 and four rectangular coils 20, 30, 21, 31. Each core window has two of the coils passing through it and these two coils each have a semi-circular cross-section where they pass through the respective core window.

Claims: A method of making an electrical power distribution transformer which includes a core and coil assembly having a wound magnetic core (50) with a central window and electric coils (20, 30) which extend through said core window, the method including the steps of: (i) individually pre-forming each of a number of overall rectangular shape said electric coils (20, 30) so that said coil has a sector of a circle cross-section at least where it will pass through the core window, (ii) assembling the pre-formed coils together so that their circle sector cross-sectioned parts combine to form a circular section solid cylinder (20A, 30A) where they meet, and (iii) rotating a core wound from single width amorphous steel strip on to said circular section solid cylinder to form thereon an uncut said wound magnetic core having overall circular shape and rectangular cross-section, with said core window substantially filled by said coils, the method being characterised in that in step (i) said number of coils is in the range between two and four coils, and each said coil is pre-formed by winding electrical conductors (23, 25) on a respective support (1A, 1B) which provides a groove (1C) having at least in part the shape of said sector of a circle, in that after step (ii) and before step (iii) the method includes the further steps of (iv) locating a hollow first circular cylindrical mandrel (40) around said circular section solid cylinder, (v) rotating at least one second circular cylindrical mandrel having the same external diameter as said first mandrel to wind thereon a roll of continuous single or multiple thickness single width amorphous steel strip, and (vi) annealing the or each said roll of amorphous-steel strip under magnetic saturation, and in that step (iii) includes rotating the first and second mandrels to transfer the annealed amorphous steel strip as a single roll or up to four stacked co-axial rolls on to the first mandrel to form thereon said uncut wound magnetic core. A method as claimed in Claim 1, in which each said coil (20, 30) is pre-formed by winding said electrical conductors (23, 25) on a respective said support (1A, 1B) comprising a former made up of sections (1A, 1B), after which the former sections are separated for removal of the coil. A method as claimed in Claim 1, in which said first mandrel (40) is of electrically insulating material. A method as claimed in any preceding claim, in which the steel strip forming the wound magnetic core is of single thickness. A method as claimed in any preceding claim, in which the wound magnetic core consists of a single roll of steel strip. A method as claimed in any preceding claim, in which the transformer is single-phase with all said coils extending through only one said core. A method as claimed in Claim 6, in which the transformer has two said electric coils each having a semi-circular cross-section where it passes through the core window. A method or a transformer as claimed in any of Claims 1 to 5 in which the transformer is three-phase and has three said cores (50, 51, 52) and four said coils (20, 30, 21, 31), with each core window having two of said coils passing through it and these two coils each having a semi-circular cross-section where they pass through this core window.

Inventors: ALLAN DENNIS JOSEPH, GRANT JOHN VICTOR, ALLAN, DENNIS JOSEPH, GRANT, JOHN VICTOR
Applicants: GEC ALSTHOM LTD, GEC ALSTHOM LIMITED
Application year: 1992
Main classification: H01F41
IPC codes: H01F41, H01F27, H01F30