CN114600207B - Automatic manufacturing device for flat coil element for transformer - Google Patents
Automatic manufacturing device for flat coil element for transformer Download PDFInfo
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- CN114600207B CN114600207B CN201980101759.XA CN201980101759A CN114600207B CN 114600207 B CN114600207 B CN 114600207B CN 201980101759 A CN201980101759 A CN 201980101759A CN 114600207 B CN114600207 B CN 114600207B
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 46
- 238000002347 injection Methods 0.000 claims abstract description 100
- 239000007924 injection Substances 0.000 claims abstract description 100
- 239000011347 resin Substances 0.000 claims abstract description 25
- 229920005989 resin Polymers 0.000 claims abstract description 25
- 238000004080 punching Methods 0.000 claims abstract description 19
- 238000001746 injection moulding Methods 0.000 claims description 25
- 238000007665 sagging Methods 0.000 claims description 18
- 238000001514 detection method Methods 0.000 claims description 12
- 239000011248 coating agent Substances 0.000 claims description 8
- 238000000576 coating method Methods 0.000 claims description 8
- 238000000034 method Methods 0.000 description 6
- 238000010586 diagram Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 238000009413 insulation Methods 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 239000011265 semifinished product Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/061—Winding flat conductive wires or sheets
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Manufacturing & Machinery (AREA)
- Manufacturing Cores, Coils, And Magnets (AREA)
Abstract
The present invention relates to an automatic manufacturing apparatus for a flat coil element for a transformer, comprising: a first injection mold (10) for applying a resin to a flat coil (100, 200) of a coil sheet (A0) for the first time; a first-time punching machine (20) for removing the fixing piece (130) of the coil sheet (A1) coated with the resin for the first time; a second injection mold (30) for applying the resin to the first coated coil sheet (A1) after the fixing pieces (130, 230) are removed for a second time; a secondary punching machine (40) for performing secondary punching of the terminals (111, 112); and a transfer unit (50) for transferring the coil sheet (A0) to the first injection mold (10), transferring the first coated coil sheet (A1) to the first punch (20), and transferring the first punched coil sheet (A2) to the second injection mold (30).
Description
Technical Field
The present invention relates to a manufacturing apparatus for a transformer used in a charger for a communication terminal.
Background
In general, a transformer (transformer) has a primary side (primary) and a secondary side (secondary), and in general, the primary side serves as an input terminal and the secondary side serves as an output terminal.
Among transformers, a small-sized transformer for a mobile phone charger or the like uses a coil member (particularly, serving as a secondary side) wound with a triple insulated wire (triple insulated wire).
However, the coil component wound with the triple insulated wire has the following problems: since it is necessary to manually peel off the outer coating of the wire directly, mass production is difficult, and since the triple insulated wire cannot be uniformly wound, the reject ratio is high. Further, if a coil member around which triple insulated wires are wound is used as the secondary side of the small transformer, the primary side and the secondary side of the small transformer need to be spaced apart by a prescribed interval to secure a sufficient insulation withstand voltage, so that the size of the small transformer increases, and thus the leakage inductance (leakage inductance) of the small transformer increases.
In the present situation where high-speed charging such as a mobile phone is required to increase the output of the small-sized transformer, if a coil member around which a triple insulated wire is wound is used as the secondary side of the small-sized transformer, the primary side and the secondary side of the small-sized transformer need to be further separated from each other than in the related art to ensure sufficient insulation withstand voltage between the primary side and the secondary side, and thus the size of the small-sized transformer is further increased, and leakage inductance is also further increased. Also, as the interval between the primary side and the secondary side increases, the efficiency of the small transformer may decrease.
Therefore, it has been recently attempted to use a plate coil (plate coil) in a transformer.
The method of manufacturing such a planar coil is briefly described.
Inlay the flat coil after the first injection mold and carry out inlay injection molding, then carry out the first blanking operation in order to get rid of the unnecessary part in the flat coil that has already gone through inlay injection molding operation, after carrying out this first blanking operation, carry out the second injection molding operation in order to inlay it in the second injection mold, then carry out the second blanking operation, separate the product through cutting the terminal of the flat coil that accomplishes the second injection molding operation.
However, in the conventional method for manufacturing the flat coil, after each injection molding operation or blanking operation, the worker is required to insert the semi-finished product one by one to the next step, and thus the labor cost is high, and there are problems of low productivity and high cost of the product.
Prior art document 1: korean laid-open patent No. 2013-0106300 (publication date: 2013, 09, 27 days)
Prior art document 2: korean laid-open patent No. 2016-0041837 (publication date: 18 of 2016, 04)
Disclosure of Invention
Technical problem
The present invention has been made to solve the above-described problems of the prior art, and an object of the present invention is to provide an automatic manufacturing apparatus for a flat coil element for a transformer, which is suitable for use in the following.
First, by automatically performing the insert injection molding process and the blanking process on one production line, productivity of the flat coil element for the transformer can be improved and cost can be reduced;
secondly, the coil sheet can be positioned at the accurate positions of the injection mold and the blanking machine through the arrangement of the transfer component and the control box;
thirdly, by arranging the downward sagging part, the transfer can be accurately carried out without being influenced by other processes;
fourth, by arranging the plate coils in two rows up and down on the plate coil sheet and connecting the two rows of plate coils through the center locator, the center position can be accurately located when being embedded in the first injection mold, thereby being capable of being more accurately installed in the first injection mold, precisely performing the first-time embedded injection molding operation (improving the reliability of the first injection molding operation), and solving the problem that the existing single plate coil is distorted during the press working, and solving the problem of disqualification caused by shaking when being embedded and installed in the mold.
Solution for solving the problem
An automatic manufacturing apparatus for a planar coil component for a transformer according to the present invention for achieving the above object is characterized by comprising: a feed roller wound with a flat coil sheet having a plurality of flat coils, terminating at one terminal after starting a spiral pattern portion, and formed with a fixing sheet connected across between the spiral pattern portions; a first injection mold for applying resin to the flat coil of the coil sheet mounted by the first inlay injection molding when the flat coil sheet wound around the feed roller is inlaid and mounted, so that the fixing pieces and terminals of the flat coil are exposed; a first blanking machine that performs first blanking so as to remove a fixing piece of a coil sheet subjected to first coating of the resin (hereinafter referred to as a "first coated coil sheet"); a second injection mold for applying resin to the flat coil except for the terminal by a second insert injection in a first-time applied coil sheet (referred to as a "first-time punched coil sheet") after the fixing piece is removed by the first-time punching machine, thereby forming a flat coil element; a second punching machine for punching out the terminals for the second time in the coil sheet subjected to the second coating of the resin (hereinafter referred to as "second coated coil sheet") so as to separate the terminals from the frame bars of the second coated coil sheet, thereby separating the flat coil element from the second coated coil sheet; and a transfer unit that transfers the coil sheet wound around the feed roller to a first injection mold, transfers the first coated coil sheet to a first punch, transfers the first punched coil sheet to a second injection mold, and transfers the second coated coil sheet to the second punch.
ADVANTAGEOUS EFFECTS OF INVENTION
The automatic manufacturing apparatus of the flat coil element for a transformer of the present invention having the above-described configuration has the following effects:
first, by automatically performing the insert injection molding process and the blanking process on one production line, productivity of the flat coil element for the transformer can be improved and cost can be reduced;
secondly, the coil sheet can be positioned at the accurate positions of the injection mold and the blanking machine through the arrangement of the transfer component and the control box;
thirdly, by arranging the downward sagging part, the transfer can be accurately carried out without being influenced by other processes;
fourth, through disposing two rows of flat plate coils up and down, and connect these two rows of flat plate coils through the centre locator, can position the centre position accurately while inlaying in the first injection mold, thus can install in the first injection mold more accurately, inlay the injection molding operation (improve the reliability of the first injection molding operation) accurately for the first time;
fifth, by adopting a pair of upper and lower plate coils, the problem of twisting of the existing single plate coil at the time of press working can be solved, and when it is fitted and mounted in a mold, the problem of disqualification due to shaking can be solved.
Drawings
Fig. 1 is a conceptual block diagram of an apparatus for automatically manufacturing a flat coil element for a transformer according to an embodiment of the present invention;
FIG. 2 is a block diagram showing the main construction of an apparatus for automatically manufacturing a flat coil component for a transformer according to an embodiment of the present invention;
fig. 3 is a conceptual view of a structural example of a transfer member in an automatic manufacturing apparatus of a flat coil element for a transformer according to an embodiment of the present invention, wherein part (a) of fig. 3 is a conceptual view transferred by a transfer gear, and part (b) of fig. 3 is a conceptual view transferred a coil sheet a by a linear grab G2;
fig. 4 is a structural view of a flat coil sheet A0 wound around a feed roller Rm and fitted in a first injection mold 10 in an automatic manufacturing apparatus of a flat coil element for a transformer according to an embodiment of the present invention;
fig. 5 is an enlarged view of a main portion of fig. 4;
fig. 6 is a block diagram of a first coated coil sheet A1 after passing through a first injection mold 10 in an automatic manufacturing apparatus of a flat coil element for a transformer according to an embodiment of the present invention;
fig. 7 is a block diagram of a first punched coil sheet A2 after removing the center locator, the fixing pieces 130, 230 and the side connection pieces 410, 420 in an automatic manufacturing apparatus of a flat coil element for a transformer according to an embodiment of the present invention;
fig. 8 is a structural view of a second coated coil sheet A3 after passing through a second injection mold 30 in an automatic manufacturing apparatus of a flat coil element for a transformer according to an embodiment of the present invention;
fig. 9 is a block diagram of another example of a flat coil sheet A0 wound around a feed roller Rm and fitted in a first injection mold 10 in an automatic manufacturing apparatus of a flat coil element for a transformer according to an embodiment of the present invention.
Detailed Description
Preferred embodiments of an apparatus for automatically manufacturing a flat coil element for a transformer according to the present invention will be described in detail with reference to the accompanying drawings.
An automatic manufacturing apparatus of a flat coil component for a transformer according to an embodiment of the present invention is characterized by including a feed roller Rm, a first injection mold 10, a first punch 20, a second injection mold 30, a second punch 40, and a transfer unit 50.
In the feed roller Rm, a flat coil sheet A0 having a plurality of flat coils 100 is wound, the flat coils 100 start from one terminal 111 to form a spiral pattern portion 113 and then end at the other terminal 112, and a fixing piece 130 is formed to cross between the spiral pattern portions 113.
The configuration of the flat coil sheet A0 wound around the feed roller Rm will be described in detail.
As shown in fig. 9, the flat coil sheet A0 is basically configured such that a plurality of flat coils 100 are formed in a row in the flat coil sheet A0 shown in fig. 9, and a pair of terminals 111 and 112 and a fixing piece 130 connected across the spiral pattern portion 113 and the spiral pattern portion 113 are formed in the row of flat coils 100.
In the flat coil sheet A0 shown in fig. 9, the leg bars 510 connected to the terminals 111 are formed, and the pitch holes h1 are formed at equal intervals in the leg bars 510.
Further, another modified configuration of the flat coil sheet A0 is shown in fig. 4, in the flat coil sheet A0 shown in fig. 4, the flat coils 100, 200 are arranged in two rows, the two rows of flat coils 100, 200 are opposed to each other on the upper side and the lower side, and a center locator 300 connecting the flat coil 100 on the upper side and the flat coil 200 on the lower side is formed in the flat coil sheet A0.
In the case of the flat coil sheet A0 shown in fig. 4, if the flat coils 100, 200 are moved when fitted to the first injection mold 10, precise injection cannot be achieved, and in order to enable precise injection, the center locator 300 is formed to prevent the upper and lower flat coils 100, 200 from being moved.
In the case of the flat coil sheet A0 shown in fig. 4, there are formed up and down 2 hanger bars 510 connected to the terminals 111, 211 of the flat coil, and a plurality of pitch holes h1 are formed at equal intervals in the hanger bars 510 as in the example of fig. 9.
In the case of the flat coil sheet A0 shown in fig. 4, the connection frame bar 530 of the connection frame bar 510 is formed, and the side connection pieces 410, 420 connecting the flat coils 100, 200 and the connection frame bar 530 are formed.
Of course, the one-row flat coil sheet A0 shown in fig. 9 and the two-row flat coil sheet A0 shown in fig. 4 are both configurations of the manufacturing apparatus of the present invention.
Therefore, any one may be adopted, and the description will be given below taking as an example two rows of flat coil sheets A0 shown in fig. 4, but the same applies to one row of flat coil sheets A0 shown in fig. 9.
The first injection mold 10 is configured such that, when the flat coil sheet A0 wound around the feed roller Rm is inlaid and mounted, resin is first applied to the flat coils 100, 200 of the inlaid and mounted coil sheet A0 by first inlay injection molding so that the fixing pieces 130, 230 and the terminals 111, 112, 211, 212 (including the center locator 300 and the side connection pieces 410, 420 in the case of fig. 4) of the flat coils 100, 200 are exposed, that is, first applied to portions other than the fixing pieces 130, 230 and the terminals 111, 112, 211, 212 (the center locator 300 and the side connection pieces 410, 420 in the case of fig. 4).
The first punching machine 20 is configured such that a coil sheet A1 coated with a resin for the first time (hereinafter referred to as a "first coated coil sheet A1") is transferred to the first punching machine 20, and the first punching is performed so as to remove the fixing pieces 130, 230 (including the center positioner 300 and the side connecting pieces 410, 420 in the case of fig. 4) of the first coated coil sheet A1.
The second injection mold 30 is configured such that, when the first coated coil sheet A1 (referred to as "first-time blanked coil sheet A2") from which the fixing pieces 130, 230 are removed by the first-time blanker 20 is fitted and mounted inside the mold by transfer by the transfer unit 50, resin is coated a second time to the entire flat coil 100, 200 except for the terminals 111, 112, 211, 212 by the second-time fitted injection molding, thereby forming the flat coil elements 100', 200'.
The secondary punching machine 40 is configured such that a coil sheet A3 subjected to the secondary coating of the resin (hereinafter referred to as "secondary coated coil sheet A3") is transferred to the secondary punching machine 40 by the transfer unit 50, and the terminals 111, 112, 211, 212 are secondarily punched so as to separate the terminals 111, 112, 211, 212 of the secondary coated coil sheet A3 from the rack bar 510 of the secondary coated coil sheet A3, thereby separating the flat coil elements 100', 200' from the secondary coated coil sheet A3.
The transfer unit 50 is configured to transfer the coil sheet A0 wound around the feed roller Rm to the first injection mold 10, transfer the first coated coil sheet A1 to the first punch 20, transfer the first punched coil sheet A2 to the second injection mold 30, and transfer the second coated coil sheet A3 to the second punch 40.
According to the configuration as described above, there is an effect that the flat coil sheet A0 can be automatically injection-molded for the first and second times and blanked for the first and second times on one production line, thereby forming the flat coil elements 100', 200' as a completed product.
Therefore, there is an effect that the productivity of the product can be improved and the cost can be reduced.
The flat coil sheet A0, the first-time coated coil sheet A1, the first-time punched coil sheet A2, and the second-time coated coil sheet A3 are names named in each process, and these configurations are collectively referred to as coil sheets a.
In the automatic manufacturing apparatus of the flat coil element for the transformer according to an embodiment of the present invention, the transfer unit 50 includes a first transfer part 52, a second transfer part 54, and a third transfer part 56.
The first transfer member 52 is configured to be provided at a front end or a rear end of the first injection mold 10, unwind (unwind) the flat coil sheet A0 wound around the feed roller Rm, and accurately transfer the flat coil sheet A0 to a first reference position of the first injection mold 10.
The first punch 20 and the second injection mold 30 are separated by a predetermined distance.
The second transfer member 54 is disposed at the front end or the rear end of the first injection mold 10, and is configured to accurately transfer the first coated coil sheet A1 to the second reference position of the first punch 20 and to accurately transfer the first punched coil sheet A2 to the third reference position of the second injection mold 30.
The third transfer member 56 is disposed at the front end or the rear end of the second die cutter 40, and is configured to accurately transfer the second coated coil sheet A3 to the fourth reference position of the second die cutter 40.
An automatic manufacturing apparatus of a flat coil element for a transformer according to an embodiment of the present invention is characterized by further comprising: a first injection driving part 12 for driving the first injection mold 10; a second injection driving part 32 for driving the second injection mold 30; a first blanking drive unit 22 for driving the first punch 20; a second blanking drive unit 42 for driving the second blanking machine 40; and a control box 70.
In the control box 70, a first transfer control signal for transferring the flat coil sheet A0 to a first reference position of the first injection mold 10 is output to the first transfer member 52, a second transfer control signal for transferring the first coated coil sheet A1 to a second reference position of the first punching machine 20 and a third reference position of the second injection mold 30 is output to the second transfer member 54, and a third transfer control signal for transferring the second coated coil sheet A3 to a fourth reference position of the second injection mold 30 is output to the third transfer member 56.
In the control box 70, when the flat coil sheet A0 is transferred to the first reference position of the first injection mold 10 by outputting the first transfer control signal, a first mold drive control signal is output to the first injection driving unit 12, when the first coated coil sheet A1 is transferred to the second reference position of the first blanking machine 20 by outputting the second transfer control signal, a first blanking drive control signal is output to the first blanking driving unit 22, when the first blanking coil sheet A2 is transferred to the third reference position of the second injection mold 30 by outputting the second transfer control signal, a second mold drive control signal is output to the second injection driving unit 32, and when the second coated coil sheet A3 is transferred to the fourth reference position of the second blanking machine 40 by outputting the third transfer control signal, a second blanking drive control signal is output to the second blanking driving unit 42.
Further, the first transfer member 52, which receives the first transfer control signal from the control box 70, forcibly transfers the flat coil sheet A0 wound around the feed roller Rm to transfer the flat coil sheet A0 wound around the feed roller Rm to the first reference position of the first injection mold 10.
In the automatic manufacturing apparatus of the flat coil component for the transformer according to the embodiment of the present invention, the second transfer part 54, which receives the second transfer control signal from the control box 70, forcibly transfers the first coated coil sheet A1 to transfer the first coated coil sheet A1 to the second reference position of the first blanking machine 20, and forcibly transfers the first coated coil sheet A1 to transfer the first blanked coil sheet A2 to the third reference position of the second injection mold 30.
The third transfer member 56, which receives the third transfer control signal from the control box 70, forcibly transfers the second-time coated coil sheet A3 to transfer the second-time coated coil sheet A3 to the fourth reference position of the second blanking machine 40.
The first injection driving part 12, which receives the first mold driving control signal from the control box 70, assembles the first injection mold 10 such that the first injection mold 10 applies the resin to the coil sheet a inlaid and mounted at the first reference position for the first time through the first inlaid injection.
The first blanking driving part 22, which receives the first blanking driving control signal from the control box 70, drives the first blanking machine 20 such that the first blanking machine 20 performs the first blanking of the fixing pieces 130, 230 of the first coated coil sheet A1 located at the second reference position.
The second injection driving part 32, which receives the second mold driving control signal from the control box 70, assembles the second injection mold 30 such that the second injection mold 30 secondarily applies the resin to the first blanked coil sheet A2, which is inlaid and mounted at the third reference position, through the second inlaid injection.
The second blanking driving part 42, which receives the second blanking driving control signal from the control box 70, drives the second blanking machine 40 such that the second blanking machine 40 performs the second blanking to separate the terminals 111, 112, 211, 212 of the second coated coil sheet A3 located at the fourth reference position from the frame bars 510 of the coil sheet.
An automatic manufacturing apparatus of a flat coil component for a transformer according to an embodiment of the present invention is characterized in that, in order to prevent a pitch movement accumulated error and transfer to an accurate position, the first coated coil sheet A1 is formed with a first downward sagging portion A2a protruding downward sagging between the first injection mold 10 and the first blanking machine 20.
An automatic manufacturing apparatus of a flat coil component for a transformer according to an embodiment of the present invention is characterized in that, in order to prevent a pitch movement accumulated error and transfer to an accurate position, the second coated coil sheet A3 is formed with a second downwardly sagging portion A3a that protrudes downward from sagging between the second injection mold 30 and the second blanking machine 40.
The first support roller R1 is provided at the first downward sagging portion A2a such that the first downward sagging portion A2a is supported by the first support roller R1, and the second support roller R2 is provided at the second downward sagging portion A3a such that the second downward sagging portion A3a is supported by the second support roller R2.
The automatic manufacturing apparatus of a flat coil element for a transformer according to an embodiment of the present invention further includes a first lower limit detection sensor 62 for detecting a drop of the lower limit position of the first downward sagging portion A2a below a preset lower limit value and outputting the drop to the control box 70 as a lower limit detection signal for the drop below the preset lower limit value.
The automatic manufacturing apparatus of a flat coil element for a transformer according to an embodiment of the present invention further includes a second lower limit detection sensor 63 for detecting a drop of the lower limit position of the second downward sagging portion A3a below a preset lower limit value and outputting the drop to the control box 70 as a lower limit detection signal for the drop below the preset lower limit value.
The automatic manufacturing apparatus of the flat coil element for the transformer according to an embodiment of the present invention is characterized by further comprising a sheet detection sensor 61 provided at the front end of the first injection mold 10 to detect the presence or absence of the flat coil sheet A0.
An automatic manufacturing apparatus of a flat coil element for a transformer according to an embodiment of the present invention is characterized in that, as described above, pitch holes h1 are formed at equal intervals in a coil sheet a, and each of the transfer members 52, 54, 56 includes: a transfer gear G1 having transfer teeth G1a formed at equal intervals, inserted into the pitch hole h1, and rotated to transfer the coil sheet a; and a gear driving part (not shown) connected to the transfer gear G1 and rotating the transfer gear G1, the control box 70 driving and controlling the gear driving part by outputting a control signal to the gear driving part.
The gear drive unit may be constituted by a transmission member such as a motor or a speed reducer, for example.
An automatic manufacturing apparatus of a flat coil element for a transformer according to an embodiment of the present invention is characterized in that each of the transfer members 52, 54, 56 includes: a Linear grab (Linear grab) for pinching the coil sheet a for movement; and a linear driving part for advancing and retreating the linear grapple G2 in one direction and the other direction, the control box 70 driving and controlling the linear driving part by outputting a control signal to the linear driving part.
On the other hand, after the first injection is completed, the first injection driving part 12 drives and controls the first injection mold 10 to return to the original position, after the second injection is completed, the second injection driving part 32 drives and controls the second injection mold 30 to return to the original position, after the first blanking is completed, the first blanking driving part 22 drives and controls the first blanking machine 20 to return to the original position, and after the second blanking is completed, the second blanking driving part 42 drives and controls the second blanking machine 40 to return to the original position.
A method of manufacturing a planar coil member for a transformer according to an embodiment of the present invention having the configuration described above is described below.
For example, a metal sheet is processed by rolling or press blanking, and a flat coil sheet A0 is formed and wound around the feed roller Rm.
When the first transfer member 52 is operated based on the control of the control box 70 and transfers only the preset pitch, the flat coil sheet A0 is located at the first reference position of the first injection mold 10.
When the first injection driving part 12 is operated based on the control of the control box 70, the movable mold of the first injection mold 10 is moved and assembled with the fixed mold, and then the resin is injected, forming the first coated coil sheet A1.
The first coated coil sheet A1 is formed by injecting an injection molding resin such that the center locator 300 and the fixing pieces 130, 230 and the terminals 111, 112, 211, 212 are exposed, that is, such that portions other than the center locator 300, the fixing pieces 130, 230, and the terminals 111, 112, 211, 212 are coated with an insulating resin.
Thereafter, when the second transfer member 54 is operated based on the control of the control box 70 and transfers only the preset pitch, the flat coil sheet A0 is aligned with the second reference position of the first punch 20 and the third reference position of the second injection mold 30.
A first blanking process is performed to remove the center locator 300, the fixing pieces 130, 230, and the side connection pieces 410, 420 from the first coated coil sheet A1 aligned with the second reference position.
The first punched coil sheet A2 from which the center locator 300, the fixing pieces 130, 230, and the side connecting pieces 410, 420 are removed is fitted and mounted to the second injection mold 30.
Then, the second coated coil sheet A3 is formed by injecting resin into the region other than the terminals 111, 112, 211, 212, and at this time, the flat coil elements 100', 200' for the transformer are completed.
Finally, the third transfer member 56 operates to pull the second coated coil sheet A3 into alignment with the fourth reference position of the second die cutter 40.
The terminals 111, 112, 211, 212 are cut from the rack bar 510, thereby separating and taking out the flat coil elements 100', 200' for the transformer.
As described above, it is apparent to those skilled in the art that the present invention can be embodied in other specific forms without departing from the spirit or scope of the present invention, in addition to the foregoing embodiments, according to the preferred embodiments of the present invention.
In the automatic manufacturing apparatus of the flat coil element for a transformer according to the embodiment of the present invention, the flat coil formed of the upper and lower rows is described as an example, but the present invention is not limited thereto, and it is needless to say that a case of forming three or more rows may be a manufacturing object, for example.
The foregoing embodiments are therefore to be considered in all respects as illustrative and not restrictive, and the invention is therefore not to be limited to the foregoing description, but may be modified within the scope and equivalents of the appended claims.
Claims (8)
1. An automatic manufacturing device of a flat coil element for a transformer is characterized in that,
comprising the following steps:
a feed roller (Rm) wound with a flat coil sheet (A0) having a plurality of flat coils (100), the flat coils (100) starting from one terminal (111) to form a spiral pattern portion (113) and ending at the other terminal (112), and formed with a fixing piece (130) connected across between the spiral pattern portions (113);
a first injection mold (10) for applying resin to the flat coil (100) of the coil sheet (A0) mounted by first mosaic injection molding when the flat coil sheet (A0) wound around the feed roller (Rm) is mosaic-mounted so that the fixing piece (130) and the terminals (111, 112) of the flat coil (100) are exposed;
a first punching machine (20) for performing first punching so as to remove a fixing piece (130) of the coil sheet (A1) subjected to the first resin coating, the coil sheet (A1) subjected to the first resin coating being hereinafter referred to as a first-coated coil sheet (A1);
a second injection mold (30) for forming a flat coil element (100') by applying a resin to the flat coil (100) other than the terminals (111, 112) by a second insert injection molding in a first-time applied coil sheet (A1) after the fixing piece (130) is removed by the first-time punch (20), the first-time applied coil sheet (A1) after the fixing piece (130) is removed by the first-time punch (20) being hereinafter referred to as a first-time punched coil sheet (A2);
a second punching machine (40) for punching the terminals (111, 112) for the second time in the coil sheet (A3) subjected to the second resin coating so as to separate the terminals (111, 112) from the frame bars (510) of the second coated coil sheet (A3) and thereby separate the flat coil element (100') from the second coated coil sheet (A3), the coil sheet (A3) subjected to the second resin coating being hereinafter referred to as a second coated coil sheet (A3); and
a transfer unit (50) for transferring the flat coil sheet (A0) wound around the feed roller (Rm) to a first injection mold (10), transferring the first coated coil sheet (A1) to a first punch (20), transferring the first punched coil sheet (A2) to a second injection mold (30), transferring the second coated coil sheet (A3) to the second punch (40),
wherein the first punching machine (20) and the second injection mold (30) are separated by a prescribed distance,
the transfer unit (50) includes:
a first transfer member (52) provided at the front end or the rear end of the first injection mold (10) for unwinding a flat coil sheet (A0) wound around the feed roller (Rm) and transferring the flat coil sheet (A0) to a first reference position of the first injection mold (10);
a second transfer member (54) provided at the front end or the rear end of the first injection mold (10) and configured to accurately transfer the first coated coil sheet (A1) to a second reference position of the first punch (20) and to transfer the first punched coil sheet (A2) to a third reference position of the second injection mold (30); and
a third transfer member (56) provided at the front end or the rear end of the second punching machine (40) and configured to transfer the second coated coil sheet (A3) to a fourth reference position of the second punching machine (40),
the automatic manufacturing device of the flat coil element for the transformer further comprises:
a first injection driving part (12) for driving the first injection mold (10);
a second injection driving part (32) for driving the second injection mold (30);
a first blanking drive unit (22) for driving the first blanking machine (20);
a second blanking drive unit (42) for driving the second blanking machine (40); and
a control box (70) outputting a first transfer control signal for transferring the flat coil sheet (A0) to a first reference position of a first injection mold (10) to the first transfer part (52), outputting a second transfer control signal for transferring the first coated coil sheet (A1) to a second reference position of a first injection molding machine (20) and a third reference position of a second injection mold (30) to the second transfer part (54), outputting a third transfer control signal for transferring the second coated coil sheet (A3) to a fourth reference position of the second injection molding machine (40) to the third transfer part (56), outputting a first mold drive signal to the first injection driving part (12) when transferring the flat coil sheet (A0) to the first reference position of the first injection mold (10) by outputting the first transfer control signal, outputting a first coated coil sheet (A1) to the first injection molding machine (20) by outputting the second transfer control signal, outputting a second injection driving signal to the first injection molding machine (32) when transferring the second coated coil sheet (A3) to the fourth reference position of the second injection molding machine (40) by outputting the first transfer control signal to the first injection driving part (2), when the second coated coil sheet (A3) is transferred to a fourth reference position of a second blanking machine (40) by outputting the third transfer control signal, a second blanking drive control signal is outputted to the second blanking drive section (42),
a first transfer part (52) receiving a first transfer control signal from the control box (70) forcibly transfers the flat coil sheet (A0) wound around the feed roller (Rm) to transfer the flat coil sheet (A0) wound around the feed roller (Rm) to a first reference position of the first injection mold (10),
a second transfer member (54) receiving a second transfer control signal from the control box (70) forcibly transfers the first coated coil sheet (A1) to transfer the first coated coil sheet (A1) to a second reference position of the first blanking machine (20), and forcibly transfers the first coated coil sheet (A1) to transfer the first blanked coil sheet (A2) to a third reference position of the second injection mold (30),
a third transfer member (56) that receives a third transfer control signal from the control box (70) forcibly transfers the second coated coil sheet (A3) to transfer the second coated coil sheet (A3) to a fourth reference position of the second blanking machine (40),
a first injection driving part (12) receiving a first mold driving control signal from the control box (70) assembles the first injection mold (10) so that the first injection mold (10) applies resin to a flat coil sheet (A0) inlaid and mounted at a first reference position for the first time through first inlaid injection molding,
a first blanking driving part (22) receiving a first blanking driving control signal from the control box (70) drives the first blanking machine (20) so that the first blanking machine (20) performs first blanking on a fixing sheet (130) of the first coated coil sheet (A1) positioned at a second reference position,
a second injection driving part (32) receiving a second mold driving control signal from the control box (70) is provided with a second injection mold (30) so that the second injection mold (30) applies resin to the first blanking coil sheet (A2) embedded and mounted at the third reference position through the second embedding injection molding,
a second blanking drive section (42) that receives a second blanking drive control signal from the control box (70) drives the second blanking machine (40) such that the second blanking machine (40) performs second blanking to separate the terminals (111, 112) of the second coated coil sheet (A3) located at the fourth reference position from the frame bars (510) of the coil sheet.
2. The apparatus for automatically manufacturing a planar coil component for a transformer according to claim 1, wherein,
in order to prevent the pitch movement from accumulating errors and moving to an accurate position, the first-time coated coil sheet (A1) is formed with a first downward sagging portion (A2 a) protruding downward sagging between the first-time injection mold (10) and the first-time blanking machine (20).
3. The apparatus for automatically manufacturing a planar coil component for a transformer according to claim 1, wherein,
in order to prevent the pitch movement from accumulating errors and being transferred to an accurate position, the second coated coil sheet (A3) is formed with a second downwardly depending portion (A3 a) which protrudes downward and depends between the second injection mold (30) and a second blanking machine (40).
4. The apparatus for automatically manufacturing a planar coil component for a transformer according to claim 2, wherein,
the control box (70) further comprises a first lower limit position detection sensor (62) for detecting that the lower limit of the first downward sagging portion (A2 a) is lower than a preset lower limit value and outputting the lower limit detection signal to the control box as a lower limit detection signal when the lower limit of the first downward sagging portion is lower than the preset lower limit value.
5. An apparatus for automatically manufacturing a planar coil component for a transformer as recited in claim 3 wherein,
the control box (70) further comprises a second lower limit detection sensor (63) for detecting that the lower limit of the second downward sagging portion (A3 a) is lowered below a preset lower limit value, and outputting the lower limit detection signal to the control box as a lower limit detection signal for the condition that the lower limit of the second downward sagging portion is lowered below the preset lower limit value.
6. The apparatus for automatically manufacturing a planar coil component for a transformer according to claim 1, wherein,
the injection molding machine further comprises a sheet detection sensor (61) which is arranged at the front end of the first injection mold (10) and used for detecting whether a flat coil sheet (A0) exists.
7. The apparatus for automatically manufacturing a planar coil component for a transformer according to claim 2, wherein,
pitch holes (h 1) are formed at equal intervals in the coil sheet (A),
the transfer member (52, 54, 56) includes:
a transfer gear (G1) inserted into the pitch hole (h 1) and rotated to transfer the coil sheet (A); and
a gear driving part connected to the transfer gear (G1) and rotating the transfer gear (G1),
the control box (70) drives and controls the gear driving part by outputting a control signal to the gear driving part.
8. The apparatus for automatically manufacturing a planar coil component for a transformer according to claim 1, wherein,
the transfer member (52, 54, 56) includes:
a linear grab (G2) for pinching the coil sheet (A) for movement; and
a linear driving part for advancing and retreating the linear grapple (G2) in one direction and the other direction,
the control box (70) drives and controls the linear driving section by outputting a control signal to the linear driving section.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/KR2019/014945 WO2021090973A1 (en) | 2019-11-06 | 2019-11-06 | Apparatus for automatically manufacturing flat coil element for transformer |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN114600207A CN114600207A (en) | 2022-06-07 |
| CN114600207B true CN114600207B (en) | 2023-11-17 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201980101759.XA Active CN114600207B (en) | 2019-11-06 | 2019-11-06 | Automatic manufacturing device for flat coil element for transformer |
Country Status (2)
| Country | Link |
|---|---|
| CN (1) | CN114600207B (en) |
| WO (1) | WO2021090973A1 (en) |
Citations (6)
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|---|---|---|---|---|
| CN101599347A (en) * | 2009-06-17 | 2009-12-09 | 北京科耐特科技有限公司 | Coil board and production method thereof and the method for producing multi-layer planar transformer |
| JP2016509173A (en) * | 2013-02-07 | 2016-03-24 | ニューオンダー スペシャル エレクトリック カンパニー リミテッド | Openable / closable pliers-type gear mechanism, pliers-type gear opening / closing mechanism and winding machine |
| CN106653355A (en) * | 2017-02-17 | 2017-05-10 | 东莞市奕东电子有限公司 | Automatic production line for vehicle-mounted transformer coil skeletons |
| WO2018008792A1 (en) * | 2016-07-04 | 2018-01-11 | (주)에이프로 | Plate coil for coil component and method for manufacturing coil component |
| KR20180117767A (en) * | 2017-04-19 | 2018-10-30 | 유원용 | Method for manufactruing coil element for transformer |
| KR102024849B1 (en) * | 2018-11-16 | 2019-09-24 | 주식회사 에이텀 | Planary secondary coil assembly for transformer |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR101029514B1 (en) * | 2003-11-25 | 2011-04-18 | 가부시키가이샤 산샤덴키세이사쿠쇼 | coil |
| US8237535B2 (en) * | 2010-04-16 | 2012-08-07 | World Properties, Inc. | Integral planar transformer and busbar |
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2019
- 2019-11-06 CN CN201980101759.XA patent/CN114600207B/en active Active
- 2019-11-06 WO PCT/KR2019/014945 patent/WO2021090973A1/en active Application Filing
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101599347A (en) * | 2009-06-17 | 2009-12-09 | 北京科耐特科技有限公司 | Coil board and production method thereof and the method for producing multi-layer planar transformer |
| JP2016509173A (en) * | 2013-02-07 | 2016-03-24 | ニューオンダー スペシャル エレクトリック カンパニー リミテッド | Openable / closable pliers-type gear mechanism, pliers-type gear opening / closing mechanism and winding machine |
| WO2018008792A1 (en) * | 2016-07-04 | 2018-01-11 | (주)에이프로 | Plate coil for coil component and method for manufacturing coil component |
| CN106653355A (en) * | 2017-02-17 | 2017-05-10 | 东莞市奕东电子有限公司 | Automatic production line for vehicle-mounted transformer coil skeletons |
| KR20180117767A (en) * | 2017-04-19 | 2018-10-30 | 유원용 | Method for manufactruing coil element for transformer |
| KR102024849B1 (en) * | 2018-11-16 | 2019-09-24 | 주식회사 에이텀 | Planary secondary coil assembly for transformer |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2021090973A1 (en) | 2021-05-14 |
| CN114600207A (en) | 2022-06-07 |
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