Production of toroidal magnetic circuits of high power at home. Encyclopedia of radio electronics and electrical engineering

Encyclopedia of radio electronics and electrical engineering / welding equipment

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In our time, when many have acquired a summer house or a house in the village, where welding is a necessity, there is a problem with its acquisition. Buying a factory device is complicated by its high cost.

The most time-consuming part is the manufacture of the welding transformer itself. At the same time, the manufacturer is faced with the problem of acquiring a magnetic circuit.

The following requirements are imposed on the magnetic circuit:

• sufficient cross-sectional area of ​​the magnetic circuit;
• less weight;
• maximum efficiency of the transformer when using one or another core;
• the magnetic circuit must have a sufficient window area for laying the transformer windings.

Consider a method for manufacturing toroidal magnetic circuits for high power power transformers with given dimensions, a window for windings and a cross-sectional area.

Magnetic circuits are made from various rectangular sheets of transformer steel with a ratio of sheet width to length of approximately 1:4 - 1:10 and a sheet thickness of 0,1 - 0,7 mm. These sheets, as a rule, remain after dismantling of very powerful power transformers. In addition to the indicated transformer sheets, a medical tourniquet, epoxy glue and two cylindrical smooth bodies are also needed: one with a larger diameter, the other with a smaller diameter with a diameter ratio of 3:1. Approximately it can be 2- or 3-liter glass jars and a half-liter glass bottle. The diameter of the large cylinder must correspond to the diameter of the window for laying the transformer windings (photo 1).

The whole process can be conditionally divided into a number of stages.

1. The plates are wrapped around the smaller cylinder in turn.

2. The tourniquet is cut off and its ends are sewn together so that, putting it on a large cylinder, the tourniquet is stretched.

3. The plates pre-formed on the small cylinder are placed between the large cylinder and the bundle, after putting the prepared bundle on the large cylinder. The plates are laid in a clockwise direction tightly one after the other (photo 2).

4. After laying 5 - 7 plates, a large cylinder is taken by the base and, pressing the tourniquet against a hard surface (table), the stacked plates are rolled. At the same time, the cylinder itself is rotated inside the plates. This stage is completed after the plates are tightly fitted to each other (photo 3).

5. Then the next 5 - 7 plates are inserted, and the process of their rolling is repeated similarly to step 4. Laying and fitting the plates to each other continues until the width of the formed torus corresponds to the calculated one (photo 4).

6. Then, on the end side of the stacked plates that form the width of the torus, the plates are covered with epoxide glue and left to dry. Thor is treated with glue on both sides (photo 5).

7. After the epoxy glue has hardened, the large cylinder is removed from the torus and the tourniquet is removed, while several extreme plates can be separated, they are removed (photo 6).

8. The resulting torus is placed in a cardboard casing, covered with cloth and varnished. After the varnish has dried, the transformer windings can be laid on the magnetic circuit.

During the laying of the plates (points 4 and 5), small gaps may form if the ends of the plates do not match. From experience it can be argued that they do not have a significant effect on the operation of the transformer. But it is necessary to try to keep them smaller.

If, according to the calculation, the magnetic circuit should be high, then several tori prepared in advance by the method described above are glued together with epoxy glue, placed one on top of the other.

Authors: L.A.Uryvsky, B.V.Arnauta, A.I.Yakovenko

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