JP2022070085A - Method and apparatus for manufacturing iron core member for stacked iron core transformer - Google Patents
Method and apparatus for manufacturing iron core member for stacked iron core transformer Download PDFInfo
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Abstract
Description
本発明は、積鉄心形変圧器の鉄心に用いられる鉄心部材の製造方法と、その製造方法に用いる製造装置に関するものである。 The present invention relates to a method for manufacturing an iron core member used for an iron core of a stacked iron core type transformer, and a manufacturing apparatus used for the manufacturing method.
変圧器は、電気エネルギと磁気エネルギの変換を通じて、供給電源の電圧を変化させる、日常生活に不可欠な電力機器である。この変圧器の動作時には、鉄損や銅損といったエネルギロスが生じるが、このうちの鉄損は、変圧器の鉄心に使用される軟磁性材料の磁気特性の向上によって、年々、低下する傾向にある。 A transformer is an indispensable electric power device in daily life that changes the voltage of a power supply through the conversion of electric energy and magnetic energy. When this transformer operates, energy loss such as iron loss and copper loss occurs, but the iron loss tends to decrease year by year due to the improvement of the magnetic properties of the soft magnetic material used for the iron core of the transformer. be.
例えば、方向性電磁鋼板を使用する場合、鉄心の鉄損は、結晶方位制御や比抵抗の増大、磁区細分化、板厚低減などの技術により低減されてきた。具体的には、結晶方位制御技術では、鋼の成分や製造プロセスを適正化し、結晶方位をＧｏｓｓ方位｛１１０｝＜００１＞に高度に揃えることによって、高い磁束密度と低鉄損を達成してきた。また、比抵抗の増大技術では、鋼中により多くのＳｉやＡｌを含有させ、鋼の電気抵抗を増大させることによって、鉄損の一部である渦電流損を低減してきた。しかし、鋼中にＳｉを過度に含有させると、圧延して製造することが困難となるという問題がある。また、磁区制御による低鉄損化技術では、絶縁被膜を利用して鋼板に引張応力を付与することに加えて、エッチング等で鋼板表面に溝を形成したり、レーザービームや電子ビームなどを鋼板表面に照射して線状または点列状の歪領域を形成したりする表面加工を施すことで磁区細分化を図る技術が開発され、実用化されている。また、板厚の低減技術は、板厚が減少するほど渦電流損が低減する理論に基づくものである。しかし、過度の板厚低減は、二次再結晶の発現を不安定化するだけでなく、鋼板自体の生産性の低下や、変圧器鉄心の積み作業の工数が増大するなどの問題がある。 For example, when a grain-oriented electrical steel sheet is used, the iron loss of the iron core has been reduced by techniques such as crystal orientation control, increase in resistivity, magnetic domain subdivision, and reduction of plate thickness. Specifically, in the crystal orientation control technology, high magnetic flux density and low iron loss have been achieved by optimizing the steel composition and manufacturing process and highly aligning the crystal orientation to the Goss orientation {110} <001>. .. Further, in the technique for increasing the specific resistance, the eddy current loss, which is a part of the iron loss, has been reduced by containing more Si and Al in the steel and increasing the electric resistance of the steel. However, if Si is excessively contained in the steel, there is a problem that it becomes difficult to manufacture by rolling. In addition, in the low iron loss technology by magnetic domain control, in addition to applying tensile stress to the steel sheet using an insulating film, grooves are formed on the surface of the steel sheet by etching, etc., and laser beams and electron beams are applied to the steel sheet. A technique for subdividing a magnetic domain by irradiating the surface with a surface treatment such as forming a linear or dotted strain region has been developed and put into practical use. Further, the plate thickness reduction technique is based on the theory that the eddy current loss decreases as the plate thickness decreases. However, excessive reduction in plate thickness not only destabilizes the expression of secondary recrystallization, but also has problems such as a decrease in the productivity of the steel plate itself and an increase in man-hours for stacking the transformer core.
ところで、積鉄心形変圧器の鉄損特性は、主に鉄心の材料となる軟磁性材料の磁気特性に大きく依存するため、積鉄心形変圧器の鉄損特性改善は、軟磁性材料の磁気特性の改善に頼っていた。上記軟磁性材料としては、主として方向性電磁鋼板が用いられている。この方向性電磁鋼板の製造方法としては、所定の成分組成を有する鋼を溶製し、連続鋳造等で鋼素材（スラブ）とした後、該鋼素材を熱間圧延して熱延板とし、必要に応じて熱延板焼鈍を施した後、１回の冷間圧延または中間焼鈍を挟む２回以上の冷間圧延して最終板厚の冷延板とし、該冷延板に一次再結晶焼鈍または脱炭焼鈍を兼ねた一次再結晶焼鈍を施し、鋼板表面に焼鈍分離剤を塗布した後、仕上焼鈍を施し、さらに、絶縁被膜を被成し、必要に応じて、上記冷延以降の工程あるいは最終工程で磁区細分化処理を施すという一連の工程からなる製造プロセスが確立され、また、それぞれの製造工程における最適条件もほぼ見出されている。そのため、上記製造プロセスの枠組みの中では、積鉄心形変圧器の鉄損低減はかなり難しくなってきている。一方、新しい技術開発によって、より大きな低鉄損化を図ることも提案されているが、製造性や製造コスト面での課題が多く、実用化には至っていない。 By the way, since the iron loss characteristic of the iron core type transformer largely depends on the magnetic characteristic of the soft magnetic material which is the material of the iron core, the improvement of the iron loss characteristic of the iron core type transformer is the magnetic characteristic of the soft magnetic material. Relied on improvement. As the soft magnetic material, grain-oriented electrical steel sheets are mainly used. As a method for producing this directional electromagnetic steel sheet, steel having a predetermined composition is melted and made into a steel material (slab) by continuous casting or the like, and then the steel material is hot-rolled to obtain a hot-rolled plate. After hot-rolling, if necessary, cold-rolling once or cold-rolling two or more times with intermediate baking in between to obtain a cold-rolled plate with the final thickness, and primary recrystallizing the cold-rolled plate. Primary recrystallization that also serves as annealing or decarburization annealing is performed, a quenching separator is applied to the surface of the steel sheet, then finish annealing is performed, and an insulating film is formed, and if necessary, after the above-mentioned cold rolling. A manufacturing process consisting of a series of steps of subdividing the magnetic zone in the step or the final step has been established, and the optimum conditions in each manufacturing step have been almost found. Therefore, within the framework of the above manufacturing process, it has become considerably difficult to reduce the iron loss of the iron core type transformer. On the other hand, it has been proposed to reduce iron loss by developing new technology, but there are many problems in terms of manufacturability and manufacturing cost, and it has not been put into practical use.
そこで、上記従来技術に囚われない鉄心の鉄損低減技術として、特許文献１には、変圧器のＣＩ型またはＥＩ型の鉄心部材を切り出し、歪取焼鈍した後、パルスレーザーを照射することによって、変圧器の鉄損を改善する方法が提案されている。
Therefore, as a technique for reducing iron loss of an iron core that is not bound by the above-mentioned conventional technique,
しかしながら、上記特許文献１の技術は、高い生産効率と被膜損傷抑止の観点からは好ましくないパルスレーザーを用いた方法である他、低鉄損化に重要な条件である歪取焼鈍条件が開示されていない。また、比較的小型であるＣＩ型またはＥＩ型の変圧器を対象としており、大型の変圧器にはそのまま適用することは難しいという問題がある。
However, the technique of
そこで、本発明の目的は、従来の方向性電磁鋼板の製造技術に囚われることなく、積鉄心形変圧器のより一層に鉄損低減を可能とする鉄心部材の製造方法を提案するとともに、その製造方法に用いる製造装置を提供することにある。 Therefore, an object of the present invention is to propose a method for manufacturing an iron core member capable of further reducing iron loss in a stacked iron core type transformer without being bound by the conventional technique for manufacturing a grain-oriented electrical steel sheet, and to manufacture the iron core member. The purpose is to provide a manufacturing apparatus used in the method.
発明者らは、従来技術が抱える上記の問題点に鑑み、上記した既存の確立された方向性電磁鋼板の製造プロセスの改善、すなわち、方向性電磁鋼板の鉄損特性の改善による積鉄心形変圧器の低鉄損化から目を転じて、方向性電磁鋼板から変圧器の鉄心部材を製造する方法を見直すことで積鉄心形変圧器の鉄損低減を図ることを検討した。 In view of the above-mentioned problems of the prior art, the inventors have improved the manufacturing process of the existing established grain-oriented electrical steel sheet, that is, improved the iron loss characteristics of the grain-oriented electrical steel sheet to form a steel core transformer. Turning from the low iron loss of the transformer, we examined how to reduce the iron loss of the stacked iron core type transformer by reviewing the method of manufacturing the iron core member of the transformer from the grain-oriented electrical steel sheet.
発明者らは、まず、方向性電磁鋼板を製造してから、変圧器を組み立てるまでの工程を整理した。たとえば、積鉄心形の変圧器の場合、鉄心は、コイル状に巻き取られた方向性電磁鋼板（素材コイル）を所望の幅にスリットしてスリットコイルとし、さらに、上記スリットコイルから、脚やヨークといった鉄心用の部材（鉄心部材）を斜角切断などの剪断加工によって切り出し、該切り出した鉄心部材を１枚１枚積み重ねて、鉄心を組み立て、変圧器に組み込むのが一般的である。しかし、この剪断加工を用いる方法は、鉄心部材を切り出す際、加工歪が導入され、変圧器の鉄損が増大するという問題がある。 The inventors first organized the process from manufacturing grain-oriented electrical steel sheets to assembling transformers. For example, in the case of a stacked iron core type transformer, the iron core is made by slitting a directional electromagnetic steel sheet (material coil) wound into a coil to a desired width to form a slit coil, and further, from the slit coil, a leg or a leg or a member. It is common to cut out a member for an iron core (iron core member) such as a yoke by shearing such as diagonal cutting, stack the cut out iron core members one by one, assemble the iron core, and incorporate it into a transformer. However, this method using shearing has a problem that processing strain is introduced when the iron core member is cut out, and the iron loss of the transformer increases.
一方、巻鉄心形の変圧器の場合、上記したスリットコイルをコイル状の巻鉄心に組み立てた後、歪取焼鈍を施すことが行われている。これは、巻鉄心組立時に、素材（方向性電磁鋼板）に曲げ加工が施されて大きな歪みが導入され、素材自体の鉄損が著しく大きくなるため、この歪を歪取焼鈍によって取り除くためである。しかし、この歪取焼鈍は、加工歪みが取り除かれる利点があるが、素材の方向性電磁鋼板に施された、レーザービーム照射などによる非耐熱型磁区細分化処理の効果を消失させてしまうという欠点がある。 On the other hand, in the case of a wound core type transformer, after assembling the above-mentioned slit coil into a coil-shaped wound core, strain removal annealing is performed. This is because when the wound steel core is assembled, the material (oriented electrical steel sheet) is bent to introduce a large strain, and the iron loss of the material itself becomes significantly large. Therefore, this strain is removed by strain relief annealing. .. However, although this strain-removing annealing has the advantage of removing processing strain, it has the disadvantage of eliminating the effect of the non-heat-resistant magnetic domain subdivision treatment applied to the grain-oriented electrical steel sheet of the material by laser beam irradiation or the like. There is.
そこで、発明者らは、仕上焼鈍後の方向性電磁鋼板から上記変圧器の鉄心を製造する工程を見直し、積鉄心形変圧器における鉄心部材切り出し時の加工歪みを除去し、かつ、レーザービームなどによる磁区細分化処理による鉄損低減効果をより高めることができる技術を検討した。 Therefore, the inventors reviewed the process of manufacturing the iron core of the above transformer from the grain-oriented electrical steel sheet after finish annealing, removed the processing distortion at the time of cutting out the iron core member in the stacked iron core type transformer, and also used the laser beam and the like. We investigated a technique that can further enhance the iron loss reduction effect of the magnetic domain subdivision process.
まず、発明者らは、下記表１に示した３つの積鉄心形変圧器の製造フローについて検討した。
製造フロー１は、従来の、仕上焼鈍後に絶縁被膜を被成した方向性電磁鋼板を用いて積鉄心形変圧器を製造する製造フローである。この場合、前述したように、鉄心部材切り出し時の加工歪によって変圧器の鉄損が悪化するという問題がある。
また、製造フロー２は、上記製造フロー１の絶縁被膜の被成を鉄心部材切り出し後に行うもので、鉄心部材切り出し時の加工歪は、絶縁被膜被成時の熱処理により除去できるが、この段階での絶縁被膜の被成は、大型コイルの状態で絶縁被膜を被成する従来の製造フロー１に比べて生産性が劣るという問題がある。
一方、製造フロー３は、従来の製造フロー１の鉄心部材切出しと鉄心・変圧器の組立の間に、歪取焼鈍の工程を付加した製造フローである。この製造フローは、加工歪の除去の効果を享受できる点で好ましいが、上記段階での歪取焼鈍の付加、さらには、磁区細分化処理の付加は、生産性や製造コスト面で従来の製造フロー１よりも不利となる。
First, the inventors examined the manufacturing flow of the three steel core transformers shown in Table 1 below.
The
Further, in the manufacturing flow 2, the insulating coating of the
On the other hand, the
しかしながら、発明者らは、さらに検討を重ねた結果、製造フロー３での歪取焼鈍は適切な温度領域を選択すれば短時間で実施が可能であり、製造コストの過度の増大が押さえられる可能性があること、さらに、上記歪取焼鈍では、単に加工歪みが取り除かれるだけではなく、絶縁被膜が鋼板に付与する引張応力が増大すること、さらに、上記歪取焼鈍後の鉄心部材が冷却し終えるまでの高温時にレーザービームを照射して磁区細分化処理を施すことで、効率よく磁区細分化処理を施すことができるだけでなく、高出力のレーザービーム照射でも被膜損傷を起こすことなく磁区細分化処理が可能となり、より優れた鉄損低減効果を得ることができることを見出し、本発明を開発するに至った。
However, as a result of further studies, the inventors can perform strain relief annealing in the
上記知見に基づく本発明は、厚さが０．３０ｍｍ以下の軟磁性材料から、鉄心部材を切り出して積鉄心形変圧器の鉄心部材を製造する方法において、上記切り出した鉄心部材に７００℃以上１０００℃以下の温度に１秒以上１０００秒以下保持する歪取焼鈍を施した後、該鉄心部材が冷却される際の６００℃から５０℃までの間に、該鉄心部材の圧延方向を横切る方向に、かつ、圧延方向に１～３０ｍｍの間隔を開けて繰り返しレーザービームを照射し、磁区細分化処理を施すことを特徴とする積鉄心形変圧器用鉄心部材の製造方法を提案する。 The present invention based on the above findings is a method of cutting out an iron core member from a soft magnetic material having a thickness of 0.30 mm or less to manufacture an iron core member of a stacked iron core type transformer. After strain-removing annealing at a temperature of 1 ° C. or lower for 1 second or more and 1000 seconds or less, the direction of crossing the rolling direction of the core member is between 600 ° C. and 50 ° C. when the core member is cooled. In addition, we propose a method for manufacturing an iron core member for a stacked iron core type transformer, which comprises repeatedly irradiating a laser beam with an interval of 1 to 30 mm in the rolling direction and performing a magnetic zone subdivision treatment.
本発明の積鉄心形変圧器用鉄心部材の製造方法は、上記の鉄心部材の切り出しを、剪断加工で行うことを特徴とする。 The method for manufacturing an iron core member for a stacked iron core type transformer of the present invention is characterized in that the above-mentioned iron core member is cut out by shearing.
また、本発明の積鉄心形変圧器用鉄心部材の製造方法は、上記歪取焼鈍を、窒素ガス、水素ガスおよびＡｒガスのいずれかの単体ガス、上記１以上の混合ガスの雰囲気、あるいは、ＤＸガスまたはＲＸガスの雰囲気、上記いずれかのガスの真空度が１０４Ｐａ以下である減圧雰囲気、および、真空度が１０３Ｐａ以下である減圧大気雰囲気のいずれかの雰囲気下で施すことを特徴とする。 Further, in the method for manufacturing an iron core member for a stacked iron core type transformer of the present invention, the strain-removing evacuation is performed by a single gas of any one of nitrogen gas, hydrogen gas and Ar gas, an atmosphere of a mixed gas of 1 or more, or DX. It is characterized by the atmosphere of a gas or RX gas, a reduced pressure atmosphere in which the vacuum degree of any of the above gases is 104 Pa or less, and a reduced pressure atmosphere in which the vacuum degree is 103 Pa or less. And.
また、本発明の積鉄心形変圧器用鉄心部材の製造方法は、上記歪取焼鈍後の鉄心部材にレーザービームを照射して磁区細分化処理をする際、鉄心部材の部位に応じて、レーザービームの出力、走査速度、圧延方向の繰り返し間隔および圧延方向とレーザービームの走査方向とがなす角のうちの少なくとも１つを変化させることを特徴とする。 Further, in the method for manufacturing an iron core member for a stacked iron core type transformer of the present invention, when the iron core member after strain removal and annealing is irradiated with a laser beam to perform magnetic partition subdivision processing, a laser beam is used according to the portion of the iron core member. It is characterized by changing at least one of the output, the scanning speed, the repetition interval of the rolling direction, and the angle formed by the rolling direction and the scanning direction of the laser beam.
また、本発明の積鉄心形変圧器用鉄心部材の製造方法に用いる上記軟磁性材料は、耐熱型磁区細分化処理が施された方向性電磁鋼板であることを特徴とする。 Further, the soft magnetic material used in the method for manufacturing an iron core member for a stacked iron core transformer of the present invention is characterized by being a grain-oriented electrical steel sheet subjected to a heat-resistant magnetic domain subdivision treatment.
また、本発明は、厚さが０．３０ｍｍ以下の軟磁性材料から積鉄心形変圧器の鉄心となる部材を切り出すための加工設備と、上記切り出した鉄心部材を、整列し、搬送するコンベヤーと、７００℃以上１０００℃以下の温度に１秒以上１０００秒以下保持する歪取焼鈍を施すトンネル型の焼鈍炉と、必要に応じて、上記熱処理後の鉄心部材を強制冷却する冷却設備と、上記コンベヤーの搬送速度に同期して各鉄心部材の圧延方向を横切る方向に、かつ、圧延方向に１～３０ｍｍの間隔を開けてレーザービームを繰り返して照射するレーザービーム照射装置とを具備する積鉄心形変圧器用鉄心部材の製造装置である。 Further, the present invention comprises a processing facility for cutting out a member to be an iron core of a rolled iron core type transformer from a soft magnetic material having a thickness of 0.30 mm or less, and a conveyor for aligning and transporting the cut out iron core member. A tunnel-type annealing furnace that performs strain-removal annealing at a temperature of 700 ° C. or higher and 1000 ° C. or lower for 1 second or longer and 1000 ° C. or lower, and if necessary, a cooling facility that forcibly cools the iron core member after the heat treatment, and the above. A stacked iron core type provided with a laser beam irradiator that repeatedly irradiates a laser beam in a direction that crosses the rolling direction of each core member in synchronization with the transport speed of the conveyor and at intervals of 1 to 30 mm in the rolling direction. It is a manufacturing device for iron core members for transformers.
本発明によれば、積鉄心形変圧器の鉄損を従来以上に低減することができ、変圧器のエネルギ使用効率を高め、使用環境を拡大することが可能となるので、産業上、奏する効果は大である。 According to the present invention, the iron loss of the iron core type transformer can be reduced more than before, the energy utilization efficiency of the transformer can be improved, and the usage environment can be expanded. Is large.
まず、本発明を開発する契機となった実験について説明する。
＜実験１＞
プラズマ炎によって非耐熱型の磁区細分化処理が施され、表面にリン酸塩系の張力付与型絶縁被膜が被成された板厚０．２３ｍｍの方向性電磁鋼板（素材Ａ）と、磁区細分化処理が施されておらず、表面にリン酸塩系の張力付与型絶縁被膜が被成された板厚０．２３ｍｍの方向性電磁鋼板（素材Ｂ）を用意した。上記素材ＡとＢは、磁区細分化処理以外の製造条件は同じであり、圧延方向の磁束密度Ｂ８（磁場の強さ：８００Ａ／ｍにおける磁束密度）は、磁区細分化処理材が１．９３９Ｔ、磁区細分化非処理材が１．９４１Ｔとほぼ同等の値であった。両素材から、圧延方向を長さ方向とする長さ３００ｍｍ×幅１００ｍｍのＳＳＴ試験片を、剪断加工により、１セット３０枚として５セット分を切り出した後、表２に示した処理を施した後、各試験片の鉄損Ｗ１７／５０をＳＳＴ試験により測定し、３０枚の平均値を求めた。なお、上記剪断加工した試験片の端面は、すべて剪断加工面のままとした。また、表中の歪取焼鈍は、Ａｒ雰囲気下において８００℃の温度に２ｈｒ均熱保持する条件で行った。また、歪取焼鈍後の磁区細分化処理は、上記素材Ａに施したプラズマ炎を用いた方法・条件で行った。
First, the experiment that triggered the development of the present invention will be described.
<
A directional electromagnetic steel plate (material A) with a thickness of 0.23 mm, which has been subjected to a non-heat resistant type magnetic partition subdivision treatment by a plasma flame and has a phosphate-based tension-applied insulating film on the surface, and a magnetic group subdivision. A directional electromagnetic steel plate (material B) having a thickness of 0.23 mm, which had not been subjected to a chemical treatment and had a phosphate-based tension-applying insulating film coated on the surface, was prepared. The above materials A and B have the same manufacturing conditions except for the magnetic domain subdivision treatment, and the magnetic flux density B 8 (magnetic field strength: magnetic flux density at 800 A / m) in the rolling direction is 1. The value of 939T and the magnetic domain subdivided non-treated material was almost the same as that of 1.941T. From both materials, SST test pieces having a length of 300 mm and a width of 100 mm with the rolling direction as the length direction were cut out as 30 pieces per set by shearing, and then subjected to the treatment shown in Table 2. After that, the iron loss W 17/50 of each test piece was measured by the SST test, and the average value of 30 pieces was obtained. The end faces of the sheared test pieces were all left as the sheared faces. Further, the strain removing annealing in the table was performed under the condition that the temperature was kept at 800 ° C. for 2 hours evenly in an Ar atmosphere. Further, the magnetic domain subdivision treatment after strain removal annealing was performed by the method and conditions using the plasma flame applied to the material A.
表２に上記鉄損Ｗ１７／５０の測定値を併記した。上記表から、剪断加工した後、歪取焼鈍を施し、その後、磁区細分化処理を施したＮｏ．５の条件では、著しく低い鉄損値が得られていることがわかる。また、Ｎｏ．２（剪断加工ままの条件）とＮｏ．３（剪断加工後に歪取焼鈍をした条件）を比較すると、剪断加工後の磁束密度に顕著な変化は認められないことから、鉄損値の低減は、単純な加工歪み除去による磁束密度の増大によるものではないと考えられる。 Table 2 also shows the measured values of the iron loss W 17/50 . From the above table, No. 1 which was sheared, then strain-removed and annealed, and then subjected to magnetic domain subdivision treatment. It can be seen that under the condition of 5, a remarkably low iron loss value is obtained. In addition, No. 2 (conditions as sheared) and No. Comparing 3 (conditions in which strain was removed and annealed after shearing), no significant change was observed in the magnetic flux density after shearing. It is not considered to be due to.
そこで、上記原因を調査するため、Ｎｏ．２とＮｏ．３の条件の鋼板について、張力付与型絶縁被膜をアルカリで除去したときの鋼板の曲率半径を測定し、下記のStoneyの式を用いて絶縁被膜により鋼板に付与された張力を見積った。
σ＝Ｅｄ／３（１－ν）Ｒ
ここで、Ｅ：圧延方向のヤング率、ｄ：板厚（ｍｍ）、ν：ポアソン比、Ｒ：片面の被膜を除去したときの曲率半径（ｍｍ）であり、上記計算では、Ｅ：１２５ＧＰａ、ν＝０．３８とした。
また、上記計算に用いる鋼板の曲率半径Ｒは、圧延方向を長さ方向としたとき、幅：３０ｍｍ×長さ：３２０ｍｍの試験片を、図３に示したように、幅方向が水平面に垂直（鉛直）となるように固定して、鋼板の自由長さＬおよび反り量δを測定し、これらの値から下記式を用いて求めた。
Ｒ≒Ｌ２／２δ
Therefore, in order to investigate the above cause, No. 2 and No. For the steel sheet under the condition of 3, the radius of curvature of the steel sheet when the tension-applied insulating film was removed with alkali was measured, and the tension applied to the steel sheet by the insulating film was estimated using the Stoney equation below.
σ = Ed / 3 (1-ν) R
Here, E: Young's modulus in the rolling direction, d: Plate thickness (mm), ν: Poisson's ratio, R: Radius of curvature (mm) when the coating film on one side is removed. ν = 0.38.
Further, the radius of curvature R of the steel sheet used in the above calculation is a test piece having a width of 30 mm and a length of 320 mm when the rolling direction is the length direction, and the width direction is perpendicular to the horizontal plane as shown in FIG. It was fixed so as to be (vertical), the free length L of the steel sheet and the amount of warp δ were measured, and these values were calculated using the following formula.
R≈L 2 / 2δ
上記測定の結果、Ｎｏ．２の条件の鋼板の被膜張力σは１３ＭＰａであったのに対し、歪取焼鈍を施したＮｏ．３の条件の鋼板の被膜張力は１５ＭＰａであった。この結果から、歪取焼鈍には、まだ原因は十分に明らかとなっていないが、何らかのメカニズムで、絶縁被膜により付与される被膜張力を増大する効果があると推察された。 As a result of the above measurement, No. The film tension σ of the steel sheet under the condition of 2 was 13 MPa, whereas the strain-removing annealing No. The film tension of the steel sheet under the condition of 3 was 15 MPa. From this result, it was inferred that the strain-removing annealing has the effect of increasing the film tension applied by the insulating film by some mechanism, although the cause has not been fully clarified yet.
＜実験２＞
次いで、発明者らは、上記と同一の素材ＡおよびＢを用意し、図１に示した積鉄心形変圧器の鉄心を構成するすべての鉄心部材を、鉄心部材の長さ方向が圧延方向となるようにして斜角切断機で切り出し、表３に示した処理を施した後、図１に示す積鉄心形変圧器の鉄心を組み立て、変圧器の鉄損Ｗ１７／５０を測定した。なお、上記斜角切断した鉄心部材の端面は、すべて剪断加工面のままとした。また、歪取焼鈍は、Ａｒ雰囲気下において８００℃の温度で２ｈｒ均熱保持する条件で行った。また、磁区細分化処理は、前述した＜実験１＞で素材Ａに施したプラズマ炎を用いた方法・条件で行った。また、変圧器の鉄心は、外形５００ｍｍ角で、幅１００ｍｍの鋼板で構成し、積み厚約１５ｍｍ、鉄心重量約２０ｋｇとなるように、鋼板７０枚を積層して作製した。この際の積層方法は、２枚重ねの５段ステップラップ積みとした。
<Experiment 2>
Next, the inventors prepared the same materials A and B as above, and set all the core members constituting the core of the stacked iron core transformer shown in FIG. 1 in the rolling direction in the length direction of the core members. After cutting out with a bevel cutting machine and performing the treatment shown in Table 3, the iron core of the iron core type transformer shown in FIG. 1 was assembled, and the iron loss W 17/50 of the transformer was measured. The end faces of the iron core members cut at an oblique angle were all left as sheared faces. Further, the strain-removing annealing was performed under the condition that the heat was soaked for 2 hours at a temperature of 800 ° C. in an Ar atmosphere. Further, the magnetic domain subdivision treatment was performed by the method and conditions using the plasma flame applied to the material A in the above-mentioned <
上記変圧器の鉄損値の測定結果を表３中に併記したが、上記表２の単板試験の場合と同様、斜角切断した後、歪取焼鈍を施し、その後、磁区細分化処理を施した場合（Ｎｏ．４）に、著しい鉄損の低減が認められた。 The measurement results of the iron loss value of the transformer are also shown in Table 3, but as in the case of the veneer test in Table 2, after bevel cutting, strain removal annealing is performed, and then magnetic domain subdivision processing is performed. When it was applied (No. 4), a significant reduction in iron loss was observed.
＜実験３＞
次に、発明者らは、適正な歪取焼鈍の条件を調査する実験を行った。
磁区細分化処理が施されていない、表面にリン酸塩系の張力付与型絶縁被膜が被成された板厚０．２３ｍｍの方向性電磁鋼板（Ｂ８＝１．９４０Ｔ）から、剪断加工によって、圧延方向の長さ３００ｍｍ、圧延直角方向の長さ１００ｍｍのＳＳＴ試験片を、１セット３０枚として数セット分切り出し、表４に示す種々の異なる条件で歪取焼鈍を模擬した熱処理を施した後、レーザービームを照射して磁区細分化処理を施し、その後、ＳＳＴ試験で鉄損Ｗ１７／５０を測定した。なお、上記剪断加工したＳＳＴ試験片の端面は、すべて剪断加工面のままとした。また、レーザービームの照射は、ビーム径０．３ｍｍ、出力１００Ｗ、圧延方向の繰り返し間隔５ｍｍで実施し、レーザービームを照射した後、照射部分を目視観察した結果、いずれの試験片にも被膜損傷は確認されなかった。また、熱処理は、均熱時間が１２０ｓまでは、トンネル炉型の連続焼鈍炉を用い、均熱時間が１２００ｓおよび７２００ｓは、バッチ焼鈍炉を用いて行った。なお、上記熱処理は、いずれもＡｒ雰囲気下で行った。また、歪取焼鈍後の磁区細分化処理は、前述した＜実験１＞で素材Ａに施したプラズマ炎を用いた方法・条件で行った。
<
Next, the inventors conducted an experiment to investigate the conditions for proper strain removal and annealing.
A directional electromagnetic steel plate (B8 = 1.940T ) with a thickness of 0.23 mm, which has not been subjected to magnetic domain subdivision treatment and has a phosphate-based tension-applied insulating film on the surface, is subjected to shearing. SST test pieces having a length of 300 mm in the rolling direction and a length of 100 mm in the direction perpendicular to the rolling were cut out as 30 pieces per set and subjected to heat treatment simulating strain removal and annealing under various different conditions shown in Table 4. After that, the magnetic domain was subdivided by irradiating with a laser beam, and then the iron loss W 17/50 was measured by the SST test. The end faces of the sheared SST test pieces were all left as sheared faces. The laser beam was irradiated with a beam diameter of 0.3 mm, an output of 100 W, and a repeating interval of 5 mm in the rolling direction. After irradiating the laser beam, the irradiated portion was visually observed. Was not confirmed. Further, the heat treatment was carried out using a tunnel furnace type continuous annealing furnace up to a soaking time of 120s, and using a batch annealing furnace for the soaking time of 1200s and 7200s. All of the above heat treatments were performed in an Ar atmosphere. Further, the magnetic domain subdivision treatment after strain removal annealing was performed by the method and conditions using the plasma flame applied to the material A in the above-mentioned <
表４中に、熱処理条件とともに、３０枚のＳＳＴ試験片の鉄損平均値を示した。この結果から、熱処理温度に関しては、鉄損改善効果は、６５０℃では認められず、７００℃以上の温度で認められた。しかし、熱処理温度を１０００℃まで高めても鉄損改善効果はほぼ飽和してしまう。よって、本発明では歪取焼鈍の均熱温度は７００℃以上１０００℃の範囲とする。また、熱処理時間に関しては、７００℃以上の温度では、均熱時間が１ｓ以上で鉄損改善効果が認められた。ただし、熱処理時間が１２００秒以上は、連続焼鈍には不向きで、バッチ焼鈍が必要になり、焼鈍後、速やかに磁区細分化処理を施すことが難しくなる。また、連続焼鈍に比べて格段の低鉄損化効果が得られるものではない。よって、本発明では、歪取焼鈍の均熱時間は、連続焼鈍に適した、１～１０００ｓの範囲とする。 Table 4 shows the average iron loss of 30 SST test pieces together with the heat treatment conditions. From this result, regarding the heat treatment temperature, the iron loss improving effect was not observed at 650 ° C., but was observed at a temperature of 700 ° C. or higher. However, even if the heat treatment temperature is raised to 1000 ° C., the iron loss improving effect is almost saturated. Therefore, in the present invention, the soaking temperature of the strain-removing annealing is in the range of 700 ° C. or higher and 1000 ° C. Regarding the heat treatment time, at a temperature of 700 ° C. or higher, an iron loss improving effect was observed when the soaking time was 1 s or longer. However, if the heat treatment time is 1200 seconds or more, it is not suitable for continuous annealing, batch annealing is required, and it becomes difficult to perform magnetic domain subdivision treatment immediately after annealing. In addition, a significantly lower iron loss effect cannot be obtained as compared with continuous annealing. Therefore, in the present invention, the soaking time of strain-removing annealing is in the range of 1 to 1000 s, which is suitable for continuous annealing.
＜実験４＞
次に、発明者らは、歪取焼鈍における雰囲気が、鉄損に及ぼす影響を調査する実験を行った。
歪取焼鈍時の雰囲気を表５のように種々に変更したこと以外は、上記＜実験３＞と同様の条件で実験を行った。表５中に、雰囲気を含めた熱処理条件と、磁区細分化処理後の鉄損Ｗ１７／５０の測定結果を示した。
<Experiment 4>
Next, the inventors conducted an experiment to investigate the effect of the atmosphere in strain relief annealing on iron loss.
The experiment was carried out under the same conditions as in <
表５からわかるように、歪取焼鈍は、窒素ガス、Ａｒガス、減圧大気（３０Ｐａ）、減圧窒素（２００Ｐａ）および水素ガスの雰囲気下で行ったが、いずれも高い鉄損低減効果を示した。ただし、より詳細に比較すると、窒素雰囲気は、他の雰囲気と比較して若干、鉄損低減効果が劣っている。したがって、鉄損低減効果をより高めるためには、窒素以外の雰囲気とすることが好ましく、特に安定的に供給可能なＡｒ雰囲気で行うことがより好ましい。また、上記表には示していないが、窒素ガスやＡｒガス、水素ガス、ＤＸガスあるいは、ＲＸガスの単独または混合ガスの減圧雰囲気でも、同様の鉄損低減効果が認められた。なお、本発明における上記「減圧雰囲気」とは、１０４Ｐａ以下の雰囲気をいう。ただし、減圧大気雰囲気の場合は、残留する酸素が絶縁張力被膜と反応し、被膜の張力付与効果を減じることから、１０３Ｐａ以下とするのが好ましい。 As can be seen from Table 5, the strain-removing annealing was performed under the atmosphere of nitrogen gas, Ar gas, reduced pressure atmosphere (30 Pa), reduced pressure nitrogen (200 Pa) and hydrogen gas, all of which showed a high iron loss reduction effect. .. However, when compared in more detail, the nitrogen atmosphere is slightly inferior in the iron loss reducing effect as compared with other atmospheres. Therefore, in order to further enhance the effect of reducing iron loss, it is preferable to use an atmosphere other than nitrogen, and it is more preferable to use an Ar atmosphere that can stably supply the material. Further, although not shown in the above table, the same iron loss reducing effect was observed in a reduced pressure atmosphere of nitrogen gas, Ar gas, hydrogen gas, DX gas, or RX gas alone or mixed gas. The above-mentioned "decompressed atmosphere" in the present invention means an atmosphere of 104 Pa or less. However, in the case of a reduced pressure atmosphere, the residual oxygen reacts with the insulating tension coating and reduces the tension applying effect of the coating , so the value is preferably 103 Pa or less.
＜実験５＞
次に、発明者らは、レーザービーム照射で磁区細分化処理を施す際の部材温度の影響を調査するため、レーザービーム照射時の部材温度を種々に変化させて、被膜損傷の有無と鉄損Ｗ１７／５０に及ぼす影響を調査し、その結果を表６に示した。ここで、表６中に示したレーザービーム径とは、最大強度の１／ｅ２幅のことをいう。また、被膜損傷の有無は、目視判定で評価し、損傷が認められた場合は×、認められない場合は〇で示した。また、鉄損Ｗ１７／５０は、圧延方向の長さが３００ｍｍ、圧延直角方向の長さが１００ｍｍの試験片３０枚をＳＳＴ試験したときの平均値である。
<Experiment 5>
Next, in order to investigate the influence of the member temperature when performing the magnetic domain subdivision treatment by laser beam irradiation, the inventors changed the member temperature at the time of laser beam irradiation in various ways to determine the presence or absence of film damage and iron loss. The effect on W 17/50 was investigated, and the results are shown in Table 6. Here, the laser beam diameter shown in Table 6 means a width of 1 / e2 of the maximum intensity. The presence or absence of film damage was evaluated by visual judgment, and when damage was observed, it was indicated by x, and when it was not observed, it was indicated by ◯. Further, the iron loss W 17/50 is an average value when 30 test pieces having a length in the rolling direction of 300 mm and a length in the direction perpendicular to the rolling of 100 mm are subjected to an SST test.
表６の結果から、レーザービーム出力が小さいと、鉄損低減効果が十分に得られないこと、一方、レーザービーム出力を大きくし過ぎると、鉄損低減効果は増大するが、被膜損傷を起こすようになること、しかし、レーザービームを照射する鉄心部材の温度を高めると、高いレーザー出力までレーザービーム照射による被膜損傷が生じない傾向があることがわかる。したがって、レーザービーム照射で磁区細分化処理する場合は、前工程の歪取焼鈍が完了し、鉄心部材の温度が完全に下がり切るまでの間に行えば、被膜損傷を起こすことなく、高出力でレーザービームを照射することができ、ひいては、磁区細分化処理の効果をより高め、より低い鉄損レベルに到達することが可能となる。具体的には、レーザービームの照射は、部材温度が５０℃以上のときに行うのが好ましい。しかし、部材温度が過度に高い場合には、歪みが十分に導入されず、磁区細分化効果が得られないため、レーザービームの照射は、部材温度が６００℃以下のときに行う必要がある。
本発明は、上記の新規な知見に基づき開発したものである。
From the results in Table 6, if the laser beam output is small, the iron loss reduction effect cannot be sufficiently obtained. On the other hand, if the laser beam output is too large, the iron loss reduction effect is increased, but the film is damaged. However, it can be seen that when the temperature of the iron core member irradiated with the laser beam is increased, the film damage due to the laser beam irradiation tends not to occur up to a high laser output. Therefore, in the case of magnetic domain subdivision processing by laser beam irradiation, if the strain removal annealing in the previous process is completed and the temperature of the iron core member is completely lowered, the output will be high without causing damage to the film. It is possible to irradiate a laser beam, which in turn enhances the effect of the magnetic domain subdivision treatment and makes it possible to reach a lower iron loss level. Specifically, it is preferable to irradiate the laser beam when the member temperature is 50 ° C. or higher. However, if the member temperature is excessively high, the strain is not sufficiently introduced and the magnetic domain subdivision effect cannot be obtained. Therefore, it is necessary to irradiate the laser beam when the member temperature is 600 ° C. or lower.
The present invention has been developed based on the above-mentioned novel findings.
次に、本発明の積鉄心形変圧器の鉄心部材の製造方法について、具体的に説明する。
＜鉄心部材の素材＞：厚さ０．３０ｍｍ以下の軟磁性材料
本発明の積鉄心形変圧器の鉄心に用いる素材は、変圧器の鉄心に一般に用いられている軟磁性材料であればよく、例えば、方向性電磁鋼板、純鉄系軟磁性材料を含めた無方向性電磁鋼板、アモルファス合金薄帯などを用いることができる。素材の形態は、コイル状であっても、予めシート状に剪断されたものであってもよい。ただし、厚さは、低鉄損を達成するため、０．３０ｍｍ以下とする。好ましくは０．２７ｍｍ以下である。
Next, a method for manufacturing an iron core member of the iron core type transformer of the present invention will be specifically described.
<Material of iron core member>: Soft magnetic material with a thickness of 0.30 mm or less The material used for the iron core of the stacked iron core type transformer of the present invention may be any soft magnetic material generally used for the iron core of the transformer. For example, grain-oriented electrical steel sheets, non-oriented electrical steel sheets including pure iron-based soft magnetic materials, amorphous alloy strips, and the like can be used. The form of the material may be a coil shape or a pre-sheared sheet shape. However, the thickness shall be 0.30 mm or less in order to achieve low iron loss. It is preferably 0.27 mm or less.
なお、上記軟磁性材料が方向性電磁鋼板である場合、磁区細分化処理による鉄損改善効果をより高めるため、磁束密度が高い鋼板であることが望ましく、例えば、Ｂ８で１．９０Ｔ以上であることが好ましい。また、鉄損特性を特に重視する場合には、鋼板表面に溝や地鉄溶融部などを形成した、耐熱型の磁区細分化処理を施した鋼板を用いることが好ましい。 When the soft magnetic material is a grain - oriented electrical steel sheet, it is desirable that the soft magnetic material is a steel sheet having a high magnetic flux density in order to further enhance the effect of improving iron loss by the magnetic domain subdivision treatment. It is preferable to have. Further, when the iron loss characteristic is particularly important, it is preferable to use a heat-resistant magnetic domain subdivided steel sheet having grooves, ground iron melted portions, etc. formed on the surface of the steel sheet.
また、素材の形態がコイル状のものを用いる場合は、剪断加工の前にスリット加工などの前工程が必要になり、プロセス全体としての素材歩留まりが低下する。また、コイルを払い出し、スリットしてからコイルに巻き取るスリット加工においては、素材の耳波などの形状不良は、蛇行や板破断を助長するため、好ましくない。したがって、素材コイルの形状は良好であることが好ましく、特に、コイル幅端部の平坦度は、幅中央部に比較して同等以上であることが好ましい。 Further, when a coiled material is used, a pre-process such as slit processing is required before shearing, and the material yield of the entire process is lowered. Further, in the slit processing in which the coil is dispensed, slit and then wound around the coil, poor shape such as ear wave of the material promotes meandering and plate breakage, which is not preferable. Therefore, it is preferable that the shape of the material coil is good, and in particular, the flatness of the coil width end portion is preferably equal to or higher than that of the width center portion.
なお、スリットコイルから払い出した素材を、そのまま後述する斜角切断により鉄心部材を切り出す場合には、スリット前の素材コイルが耳波などの形状不良を有していても、形状不良が無い場合と同等に加工することが可能である。ただし、より高い精度で斜角切断を行う場合には、斜角切断前にコイル端部をトリミングするのが好ましい。 When the iron core member is cut out from the material discharged from the slit coil by diagonal cutting, which will be described later, even if the material coil before the slit has a shape defect such as an ear wave, there is no shape defect. It can be processed in the same way. However, when performing bevel cutting with higher accuracy, it is preferable to trim the coil end portion before bevel cutting.
鉄心部材の切出し：剪断加工
上記素材である方向性電磁鋼板から、積鉄心形変圧器用の鉄心部材を切り出す方法は、剪断加工とすることが好ましい。剪断加工としては、先述した実験において採用した、現時点で最も一般的な方法である斜角切断（剪断機やライン内のスイングシャーを利用）や、金型を用いたプレス加工（打抜加工）等が挙げられる。ただし、レーザービームを用いたレーザー切断、ワイヤーカット切断などの方法を用いてもよい。また、積鉄心部材を積層する際に各部材を位置決めするため、鉄心部材内部に穴開け加工を施すことも、歪取焼鈍前の本工程において実施するのが望ましい。本発明の積鉄心形変圧器用の鉄心部材の製造装置には、これらの加工を行う加工設備が設けられる。
Cutting out the iron core member: Shearing The method of cutting out the iron core member for the cored transformer from the grain-oriented electrical steel sheet which is the above material is preferably shearing. As for shearing, bevel cutting (using a shearing machine or swing shear in the line), which is the most common method at present, adopted in the above-mentioned experiment, and press working using a die (punching). And so on. However, a method such as laser cutting using a laser beam or wire cutting may be used. Further, in order to position each member when laminating the steel core members, it is desirable to perform drilling inside the core members in this step before strain removal and annealing. The apparatus for manufacturing an iron core member for a stacked iron core type transformer of the present invention is provided with processing equipment for performing these processes.
なお、本発明の技術を適用する積鉄心形変圧器の鉄心には、特段の制限はないが、切り出し時の生産性を考慮すると、鉄心を構成する各部材の長さが１００ｍｍ以上のものであることが好ましい。 The iron core of the stacked iron core type transformer to which the technique of the present invention is applied is not particularly limited, but considering the productivity at the time of cutting out, the length of each member constituting the iron core is 100 mm or more. It is preferable to have.
歪取焼鈍：７００℃以上１０００℃以下×１ｓ以上１０００ｓ以下
次いで、上記切り出した鉄心部材は、切り出し時に導入された加工歪を除去するために歪取焼鈍を施す。この歪取焼鈍は、前述した＜実験３＞の結果から、７００℃以上１０００℃以下の温度に１ｓ以上１０００ｓ以下の時間均熱保持する条件とするのが好ましい。上記温度が７００℃未満または保持時間が１ｓ未満では、鉄損低減効果が十分に得られず、一方、１０００℃超えまたは１０００ｓ超えでは、上記効果が飽和するだけでなく、生産性やエネルギーコストの面で不利となる。好ましい均熱温度は７５０℃以上９００℃以下の範囲であり、好ましい均熱時間は２ｓ以上１２０ｓ以下の範囲である。
Strain removal annealing: 700 ° C. or higher and 1000 ° C. or lower × 1s or more and 1000s or less Next, the above-cut iron core member is subjected to strain-removal annealing in order to remove the processing strain introduced at the time of cutting. From the result of <
また、歪取焼鈍の雰囲気は、窒素ガス、水素ガスおよびＡｒガスのいずれかの単体ガス、上記１以上の混合ガスの雰囲気、あるいは、ＤＸガスまたはＲＸガスの雰囲気、上記いずれかのガスの真空度が１０４Ｐａ以下である減圧雰囲気、および、真空度が１０３Ｐａ以下である減圧大気雰囲気のいずれかの雰囲気下で施すことが好ましい。なお、本発明における上記「減圧雰囲気」とは、１０４Ｐａ以下の雰囲気をいう。ただし、減圧大気雰囲気の場合は、残留する酸素が絶縁張力被膜と反応し、被膜の張力付与効果を減じることから、１０３Ｐａ以下とするのが好ましい。 The atmosphere of strain removal and quenching is an atmosphere of a single gas of any one of nitrogen gas, hydrogen gas and Ar gas, an atmosphere of a mixed gas of one or more above, an atmosphere of DX gas or RX gas, and a vacuum of any of the above gases. It is preferable to perform the application in either a reduced pressure atmosphere having a degree of 10 4 Pa or less and a reduced pressure atmosphere having a vacuum degree of 10 3 Pa or less. The above-mentioned "decompressed atmosphere" in the present invention means an atmosphere of 104 Pa or less. However, in the case of a reduced pressure atmosphere, the residual oxygen reacts with the insulating tension coating and reduces the tension applying effect of the coating , so the value is preferably 103 Pa or less.
ここで、上記歪取焼鈍を施す熱処理炉は、切り出した鉄心部材をコンベヤー（搬送ベルト）上に乗せて搬送しながら連続的に熱処理を施すことができるトンネル型の炉を用いるのが好ましい。また、熱処理炉の加熱帯には、生産性や設備の小型化を考慮し、誘導加熱装置を設置してもよい。 Here, as the heat treatment furnace for performing the strain-removing annealing, it is preferable to use a tunnel-type furnace capable of continuously performing heat treatment while transporting the cut out iron core member on a conveyor (conveyor belt). Further, an induction heating device may be installed in the heating zone of the heat treatment furnace in consideration of productivity and miniaturization of equipment.
また、上記熱処理後の冷却方法は、炉冷または空冷としてもよいが、設備の長大化を防止する観点から、ガス冷却設備やミスト冷却設備等を設置して強制冷却を行ってもよい。この際、鉄心部材内や鉄心部材と搬送ベルト間の温度差が大きくならないようにすることが重要である。温度差があると、鉄心部材に熱歪が発生し、鉄損を増大させる原因となるからである。因みに、上記の温度差やメンテナンス性の観点からは、ミスト冷却より、ガス冷却の方が好ましい。 Further, the cooling method after the heat treatment may be furnace cooling or air cooling, but from the viewpoint of preventing the lengthening of the equipment, gas cooling equipment, mist cooling equipment, or the like may be installed to perform forced cooling. At this time, it is important not to increase the temperature difference in the iron core member or between the iron core member and the transport belt. This is because if there is a temperature difference, thermal strain is generated in the iron core member, which causes an increase in iron loss. Incidentally, from the viewpoint of the above temperature difference and maintainability, gas cooling is preferable to mist cooling.
磁区細分化処理
次いで、上記歪取焼鈍後の鉄心部材には、レーザービームを照射して非耐熱型の磁区細分化処理を施す。非耐熱型の磁区細分化処理の方法としては、レーザービームを照射する方法の他に、電子ビームを照射する方法、プラズマ炎を用いる方法、微小突起ロールを用いる方法などが知られているが、鉄損低減効果が大きく、かつ、設備的にも手軽な、レーザービームを照射する方法が最も有利である。
Magnetic domain subdivision treatment Next, the iron core member after strain removal and annealing is irradiated with a laser beam to undergo a non-heat resistant magnetic domain subdivision treatment. As a non-heat resistant magnetic domain subdivision treatment method, in addition to the method of irradiating a laser beam, a method of irradiating an electron beam, a method of using a plasma flame, a method of using a microprojection roll, and the like are known. The method of irradiating a laser beam, which has a large effect of reducing iron loss and is easy in terms of equipment, is the most advantageous.
ここで、レーザービーム照射で磁区細分化処理を施す場合は、鉄心部材をコンベヤー上で整列させる必要がある。例えば、歪取焼鈍炉から排出された鉄心部材をコンベヤー上でレーザービーム照射する場合、歪取焼鈍の前あるいは後において、サイドガイド等を用いて、鉄心部材の長さ方向（素材鋼板の圧延方向）とコンベヤーの搬送方向とが一致するように整列させる、その上で、整列させた鉄心部材の位置情報に基づいて、レーザービーム照射を施すことが重要である。 Here, when the magnetic domain subdivision process is performed by laser beam irradiation, it is necessary to align the iron core members on the conveyor. For example, when irradiating a steel core member discharged from a strain-removing annealing furnace with a laser beam on a conveyor, the length direction of the iron-core member (rolling direction of the material steel plate) using a side guide or the like before or after the strain-removing annealing. ) And the transport direction of the conveyor are aligned, and then laser beam irradiation is performed based on the position information of the aligned iron core member.
また、レーザービーム照射で磁区細分化処理を施すときは、鉄心部材が冷却を完了するまでの間に行えばよいが、前述した＜実験５＞の結果が示すように、鉄心部材の温度が高いほど、レーザービーム照射による被膜損傷を抑制することができ、高出力でのレーザービーム照射が可能となるので、十分な鉄損低減効果を得ることが可能となる。したがって、レーザービーム照射による磁区細分化処理は、鉄心部材の温度が５０℃以上のときに行う。ただし、部材温度が高過ぎると、レーザービーム照射による熱歪が回復等で消失し、歪を十分に導入することができなくなるので、上限温度は６００℃程度とする。レーザービームの照射温度は６０以上が好ましく、３００℃以下が好ましい。 Further, when the magnetic domain subdivision treatment is performed by laser beam irradiation, it may be performed until the iron core member completes cooling, but as the result of <Experiment 5> described above shows, the temperature of the iron core member is high. The more the film damage due to the laser beam irradiation can be suppressed, and the laser beam irradiation at a high output becomes possible, so that a sufficient iron loss reduction effect can be obtained. Therefore, the magnetic domain subdivision treatment by laser beam irradiation is performed when the temperature of the iron core member is 50 ° C. or higher. However, if the member temperature is too high, the thermal strain due to the laser beam irradiation disappears due to recovery or the like, and the strain cannot be sufficiently introduced. Therefore, the upper limit temperature is set to about 600 ° C. The irradiation temperature of the laser beam is preferably 60 or more, preferably 300 ° C. or lower.
また、磁区細分化処理に用いるレーザーの種類としては、ＹＡＧやＣＯ２、ファイバーレーザー等、公知のものを用いることができる。しかし、軟磁性材料として方向性電磁鋼板を用いる場合、レーザービームのビーム径が大きいと、熱影響部が大きくなって、鉄損低減効果が小さくなるため、ビーム径は小さいほど有利である。具体的には、ビーム径は、０．３ｍｍ以下が好ましく、０．２ｍｍ以下がより好ましい。斯かる観点から、軟磁性材料として方向性電磁鋼板の場合には、小径化が容易なファイバーレーザーを用いることが好ましい。ここで、上記ビーム径とは、本発明では、レーザービームの走査方向に直交する方向（走査方向が圧延直角方向の場合、圧延方向）の径のことをいい、ビーム断面が楕円状のときは、レーザービームの走査方向と平行な方向（走査方向が圧延直角方向の場合、圧延直角方向）の径は、上記値より大きくてもよい。 Further, as the type of laser used for the magnetic domain subdivision treatment, known lasers such as YAG, CO 2 and a fiber laser can be used. However, when a grain-oriented electrical steel sheet is used as the soft magnetic material, if the beam diameter of the laser beam is large, the heat-affected zone becomes large and the iron loss reducing effect becomes small, so that the smaller the beam diameter is, the more advantageous. Specifically, the beam diameter is preferably 0.3 mm or less, more preferably 0.2 mm or less. From this point of view, in the case of grain-oriented electrical steel sheets as the soft magnetic material, it is preferable to use a fiber laser whose diameter can be easily reduced. Here, in the present invention, the beam diameter means a diameter in a direction orthogonal to the scanning direction of the laser beam (when the scanning direction is a rolling orthogonal direction, the rolling direction), and when the beam cross section is elliptical. , The diameter in the direction parallel to the scanning direction of the laser beam (when the scanning direction is the rolling perpendicular direction, the rolling orthogonal direction) may be larger than the above value.
また、磁区細分化処理を施すには、レーザービームをコンベヤーの搬送方向を横切る方向に、かつ、繰り返し走査して照射し、これによって、長さ方向（圧延方向）に１～３０ｍｍの間隔（ＲＤ間隔）を開けて熱歪領域を形成することが必要である。上記熱歪領域の圧延方向の間隔が１ｍｍを下回ると、レーザービーム照射による熱歪が過度に導入され、鉄損低減効果が小さくなるばかりでなく、生産性が低下する原因ともなる。一方、３０ｍｍを超えると、十分な鉄損低減効果が得られなくなる。好ましくは３～１５ｍｍの範囲である。レーザービームの走査方向とコンベヤーの搬送方向のなす角度（０～９０°を取り得る）は、十分な磁区細分化効果を得るためには４５～９０°の範囲とすることが好ましい。 Further, in order to perform magnetic domain subdivision processing, a laser beam is repeatedly scanned and irradiated in a direction crossing the transport direction of the conveyor, whereby an interval (RD) of 1 to 30 mm in the length direction (rolling direction) is applied. It is necessary to open a space) to form a thermal strain region. If the distance between the thermal strain regions in the rolling direction is less than 1 mm, thermal strain due to laser beam irradiation is excessively introduced, which not only reduces the iron loss reducing effect but also causes a decrease in productivity. On the other hand, if it exceeds 30 mm, a sufficient iron loss reduction effect cannot be obtained. It is preferably in the range of 3 to 15 mm. The angle between the scanning direction of the laser beam and the transport direction of the conveyor (which can be 0 to 90 °) is preferably in the range of 45 to 90 ° in order to obtain a sufficient magnetic domain subdivision effect.
また、レーザービームの照射は、鉄心部材の表面上を全幅に亘って途切れることなく走査するのが好ましい。レーザービームの未照射部があると、その部分は磁区細分化効果が得られないからである。 Further, it is preferable that the irradiation of the laser beam scans the surface of the iron core member over the entire width without interruption. This is because if there is an unirradiated portion of the laser beam, the magnetic domain subdivision effect cannot be obtained in that portion.
方向性電磁鋼板の製品コイル（素材鋼板）に対して磁区細分化処理を施していた従来の方法では、１ｍ程度の幅を複数に分割し、複数のレーザービーム照射装置で磁区細分化処理を施していたため、素材の幅方向でビーム照射の欠落部が存在し、鉄損を低減する観点からは好ましくない状態であった。しかし、本発明では、レーザービームの照射対象が、切り出した鉄心部材であるため、ビーム照射間欠部が生じることなく処理することができる。 In the conventional method in which the product coil (material steel sheet) of the grain-oriented electrical steel sheet is subjected to the magnetic domain subdivision treatment, the width of about 1 m is divided into a plurality of parts, and the magnetic domain subdivision treatment is performed by a plurality of laser beam irradiation devices. Therefore, there was a missing portion of beam irradiation in the width direction of the material, which was not preferable from the viewpoint of reducing iron loss. However, in the present invention, since the irradiation target of the laser beam is the cut-out iron core member, the processing can be performed without the occurrence of the beam irradiation intermittent portion.
なお、レーザービームをコンベヤーの搬送方向に直交する方向に走査する手段としては、ポリゴンミラースキャナーやガルバノスキャナー等、公知の方法が利用できる。また、所望の圧延方向の処理間隔を得るためには、鉄心部材の搬送速度に同期させて、上記のスキャナーを駆動する必要がある。その他の照射条件であるレーザービームの出力や、走査速度、ビームフォーカス等は、所望の鉄損あるいは表面状態が得られるよう、事前に実験を行い、最適条件を決定しておくことが好ましい。 As a means for scanning the laser beam in a direction orthogonal to the transport direction of the conveyor, a known method such as a polygon mirror scanner or a galvano scanner can be used. Further, in order to obtain a processing interval in a desired rolling direction, it is necessary to drive the scanner in synchronization with the transport speed of the iron core member. It is preferable to conduct experiments in advance to determine the optimum conditions for the laser beam output, scanning speed, beam focus, etc., which are other irradiation conditions, so that the desired iron loss or surface condition can be obtained.
また、磁区細分化処理を施す鉄心部材は、鉄心を構成する各部材それぞれの形状・寸法が異なるため、事前に鉄心部材の形状・寸法を認識（把握）し、その結果をレーザー加工システムにフィードフォワードし、鉄心部材の形状・寸法に応じてレーザービーム照射を施すようにすることが好ましい。 In addition, since the iron core members to be subjected to magnetic domain subdivision processing have different shapes and dimensions of each member constituting the iron core, the shape and dimensions of the iron core members are recognized (understood) in advance and the results are fed to the laser processing system. It is preferable to forward the laser beam irradiation according to the shape and dimensions of the iron core member.
さらに、本発明においては、より鉄損低減効果を得るため、上記機能を活用し、１つの鉄心部材内の部位に応じてレーザービームの照射条件を変更することが好ましい。例えば、図２は、鉄心部材の部位に応じて、圧延方向（搬送方向）のレーザービームの走査間隔を変更しない例（図２（ａ））と変更した例（図２（ｂ））を示したものである。変更する照射条件としては、上記した圧延方向の走査間隔の他に、レーザービームの出力や走査速度、圧延方向とビームの走査方向とがなす角のうちの少なくも１つ以上の条件を挙げることができる。このような１つの鉄心部材内での処理条件の変更は、鉄心部材を切り出した後に磁区細分化処理を施す本発明においてのみ実現可能である。 Further, in the present invention, in order to further obtain the iron loss reducing effect, it is preferable to utilize the above function and change the irradiation condition of the laser beam according to the portion in one iron core member. For example, FIG. 2 shows an example in which the scanning interval of the laser beam in the rolling direction (transport direction) is not changed (FIG. 2A) and an example in which the scanning interval is changed (FIG. 2B) according to the portion of the iron core member. It is a thing. In addition to the scanning interval in the rolling direction described above, the irradiation conditions to be changed include at least one of the laser beam output and scanning speed, and the angle between the rolling direction and the scanning direction of the beam. Can be done. Such a change in the processing conditions in one iron core member can be realized only in the present invention in which the magnetic domain subdivision processing is performed after cutting out the iron core member.
鉄心の組立
磁区細分化処理を施した鉄心部材は、通常公知の方法で、変圧器の鉄心に組み立てればよい。ただし、磁区細分化処理を施した鉄心部材は、鉄心組立までの間において、剪断加工等による加工歪が導入されることがないようにするのが望ましい。
Assembling the iron core The iron core member that has been subjected to the magnetic domain subdivision treatment may be assembled into the iron core of the transformer by a commonly known method. However, it is desirable that the iron core member that has been subjected to the magnetic domain subdivision treatment does not introduce processing strain due to shearing or the like until the iron core is assembled.
板厚が０．２３ｍｍで、耐熱型の磁区細分化処理を施した方向性電磁鋼板Ａ（Ｂ８：１．９０２Ｔ）と、磁区細分化処理が施されていない方向性電磁鋼板Ｂ（Ｂ８：１．９３５Ｔ）の方向性電磁鋼板から、図１に示した形状・寸法を有する三相三脚の積鉄心形変圧器用の鉄心部材を、表７に示したように、剪断加工（斜角切断）とワイヤーカット切断の２つの方法により採取した。なお、一部の条件では、形状Ｃの部材の中心部に、金型を使った穴抜加工法で、直径３ｍｍの穴開け加工を行った。
次いで、上記切り出した鉄心部材を、金属メッシュベルトからなる搬送ベルト上に、部材同士が重ならないよう、かつ、部材の圧延方向が搬送方向に一致するようにサイドガイトで整列させた後、トンネル型の熱処理炉内に搬送し、歪取焼鈍を施した。上記熱処理炉の加熱帯では、７００℃までを誘導加熱装置で加熱し、均熱帯では、表７に記載した雰囲気下で、表７に示した温度と時間の均熱処理を施した後、６００℃までの冷却は、上記と同じ雰囲気下で炉冷し、６００℃以下の温度域の冷却は、表７に示した雰囲気下で放冷した。この際、上記冷却時の部材温度が表７に示した温度になった時点において、各鉄心部材の表面に、表７に記載した条件でレーザービームを照射し、磁区細分化処理を施した。上記レーザービームには、ファイバービームを用い、ガルバノスキャナーを用いて鉄心部材の幅方向（素材鋼板の圧延方向と直角方向）の全幅に亘って照射した。この際、一部の部材に対しては、部材位置に応じてレーザービームの照射パターンを変更した。なお、上記磁区細分化処理後の部材表面を目視観察した結果、いずれの条件においてもレーザービーム照射による被膜損傷は認められなかった。
次いで、上記磁区細分化を施した鉄心部材を用いて、前述した図１に示した三相三脚の積鉄心形変圧器用の鉄心を組み立てた。この鉄心の組み立ては、２枚重ねの５段ステップラップ積みとし、７０枚の鉄心部材を、積み厚が約１５ｍｍ、鉄心重量が約２０ｋｇとなるよう積層した。
次いで、上記組み立てた変圧器の鉄心に、１２０°位相をずらした三相で励磁し、磁束密度１．７Ｔにおける変圧器の鉄損Ｗ１７／５０を測定し、その結果を表７中に併記した。
Electrical steel sheet A (B 8 : 1.902T) with a thickness of 0.23 mm and heat-resistant magnetic domain subdivision treatment, and grain-oriented electrical steel sheet B (B 8 ) without magnetic domain subdivision treatment. From a grain-oriented electrical steel sheet of 1.935T), a core member for a three-phase three-legged steel core transformer having the shape and dimensions shown in FIG. 1 is sheared (bevel cutting) as shown in Table 7. ) And wire cutting. Under some conditions, a hole having a diameter of 3 mm was drilled in the center of the member having the shape C by a drilling method using a die.
Next, the cut-out iron core members are aligned on a transport belt made of a metal mesh belt with a side guide so that the members do not overlap each other and the rolling directions of the members match the transport direction, and then the tunnel type is used. It was transported into a heat treatment furnace and subjected to strain removal and annealing. In the heating zone of the heat treatment furnace, the temperature is heated up to 700 ° C. by an induction heating device, and in the tropics, the temperature and time shown in Table 7 are equalized under the atmosphere shown in Table 7, and then 600 ° C. is applied. The cooling up to the above was carried out in the same atmosphere as above, and the cooling in the temperature range of 600 ° C. or lower was allowed to cool in the atmosphere shown in Table 7. At this time, when the member temperature at the time of cooling reached the temperature shown in Table 7, the surface of each iron core member was irradiated with a laser beam under the conditions shown in Table 7 to perform magnetic domain subdivision treatment. A fiber beam was used as the laser beam, and a galvano scanner was used to irradiate the entire width of the iron core member in the width direction (direction perpendicular to the rolling direction of the material steel plate). At this time, for some members, the irradiation pattern of the laser beam was changed according to the position of the members. As a result of visually observing the surface of the member after the magnetic domain subdivision treatment, no film damage due to laser beam irradiation was observed under any of the conditions.
Next, the iron core for the three-phase tripod stacked iron core type transformer shown in FIG. 1 described above was assembled using the iron core member subjected to the above-mentioned magnetic domain subdivision. The core was assembled in a two-ply, five-stage step wrap stack, and 70 core members were laminated so that the stack thickness was about 15 mm and the weight of the core was about 20 kg.
Next, the iron core of the assembled transformer was excited by three phases shifted by 120 °, and the iron loss W 17/50 of the transformer at a magnetic flux density of 1.7 T was measured, and the results are also shown in Table 7. bottom.
上記表の結果から、本発明の条件を満たした鉄心部材から組み立てられた変圧器の鉄心は、鉄損特性に優れていることがわかる。特に、鉄心部材内で、位置により磁区細分化の処理パターンを変更した部材から組み立てた変圧器の鉄心は、より優れた鉄損特性を有していることがわかる。 From the results in the above table, it can be seen that the iron core of the transformer assembled from the iron core member satisfying the conditions of the present invention is excellent in iron loss characteristics. In particular, it can be seen that the iron core of the transformer assembled from the member whose magnetic domain subdivision processing pattern is changed depending on the position in the iron core member has more excellent iron loss characteristics.
本発明の技術は、三相三脚の積鉄心形変圧器用の鉄心部材のみならず、単相の積鉄心形変圧器用の鉄心部材やリアクトルの積鉄心部材など、積み重ねて使用される鉄心部材にも適用することができる。
The technique of the present invention applies not only to iron core members for three-phase three-legged iron core transformers, but also to iron core members used in a stacked manner, such as iron core members for single-phase stacked iron core transformers and reactor core members. Can be applied.
Claims (6)
上記切り出した鉄心部材に７００℃以上１０００℃以下の温度に１秒以上１０００秒以下保持する歪取焼鈍を施した後、該鉄心部材が冷却される際の６００℃から５０℃までの間に、該鉄心部材の圧延方向を横切る方向に、かつ、圧延方向に１～３０ｍｍの間隔を開けて繰り返しレーザービームを照射し、磁区細分化処理を施すことを特徴とする積鉄心形変圧器用鉄心部材の製造方法。 In a method of cutting out an iron core member from a soft magnetic material having a thickness of 0.30 mm or less to manufacture an iron core member of a stacked iron core type transformer.
After the above-cut iron core member is subjected to strain-removing annealing at a temperature of 700 ° C. or more and 1000 ° C. or less for 1 second or more and 1000 seconds or less, the temperature between 600 ° C. and 50 ° C. when the iron core member is cooled is between 600 ° C. and 50 ° C. An iron core member for a stacked iron core type transformer, which is characterized by repeatedly irradiating a laser beam in a direction crossing the rolling direction of the iron core member and at intervals of 1 to 30 mm in the rolling direction to perform magnetic domain subdivision processing. Production method.
上記切り出した鉄心部材を、整列し、搬送するコンベヤーと、
７００℃以上１０００℃以下の温度に１秒以上１０００秒以下保持する歪取焼鈍を施すトンネル型の焼鈍炉と、
必要に応じて、上記熱処理後の鉄心部材を強制冷却する冷却設備と、
上記コンベヤーの搬送速度に同期して各鉄心部材の圧延方向を横切る方向に、かつ、圧延方向に１～３０ｍｍの間隔を開けてレーザービームを繰り返して照射するレーザービーム照射装置とを具備する積鉄心形変圧器用鉄心部材の製造装置。 Processing equipment for cutting out the core member of a stacked iron core transformer from a soft magnetic material with a thickness of 0.30 mm or less, and
A conveyor that aligns and conveys the above-cut iron core members,
A tunnel-type annealing furnace that performs strain-removal annealing at a temperature of 700 ° C to 1000 ° C for 1 second to 1000 seconds, and
If necessary, a cooling facility that forcibly cools the iron core member after the heat treatment, and
A stacked iron core provided with a laser beam irradiating device that repeatedly irradiates a laser beam in a direction that crosses the rolling direction of each iron core member and at intervals of 1 to 30 mm in the rolling direction in synchronization with the transport speed of the conveyor. Manufacturing equipment for iron core members for rolling mills.
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