JP2018160502A - Method of manufacturing wound core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a wound core that can be easily handled during manufacturing.SOLUTION: A method of manufacturing a wound core according to an embodiment includes laminating an amorphous material cut by a predetermined length such that the amorphous material is formed into a U shape (S1, S2, and S3), annealing the amorphous material in a state of being formed in a U shape (S4), and closing an opening of the annealed amorphous material to form an annular shape (S6).SELECTED DRAWING: Figure 2

Description

  Embodiments of the present invention relate to a method for manufacturing a wound iron core formed by winding a ribbon-like amorphous material.

  In recent years, for example, power distribution transformers and the like have been strongly demanded for energy saving and high efficiency, such as a standard that requires high efficiency worldwide as represented by the so-called top runner system. And in order to reduce the no-load loss which generate | occur | produces in the iron core called iron loss, what uses the iron-type amorphous material as a material of an iron core is increasing.

  Such an amorphous material is formed in a ribbon shape by rapidly cooling a melted material, and desired core characteristics can be obtained by annealing after molding into a predetermined iron core shape. At this time, the amorphous material has elasticity before annealing. For example, although it is less likely to be damaged even if bent at an acute angle, the elasticity decreases after annealing, so-called tenacity decreases. When force is applied, there is a risk of scattering as small fragments. Therefore, for example, in Patent Document 1, it is proposed to prevent scattering of fragments by covering the entire wound iron core.

JP 2003-133141 A

However, the breakage of the amorphous material may occur at the time of manufacturing the wound core. For example, when an amorphous material that has been annealed is cut and laminated, the amorphous material is damaged when an opening is formed by cutting a part of a wound core that has been annealed in an annular shape. There is a risk. Therefore, conventionally, it has been necessary to handle with care when manufacturing a wound iron core.
Then, the manufacturing method of the wound iron core which can make it easy to handle at the time of manufacture is provided.

  The method of manufacturing a wound core according to the embodiment includes stacking amorphous materials cut to a predetermined length and forming them in a U shape, annealing the amorphous material in a state of being formed into a U shape, and opening the annealed amorphous material The part is closed and formed into an annular shape.

The figure which shows typically the wound iron core by 1st Embodiment. The figure which shows a part of flow of the manufacturing process of a wound iron core The figure which shows the aspect which cut | disconnects an amorphous ribbon typically The figure which shows typically the aspect which laminates | stacks an amorphous ribbon and forms in a U shape The figure which shows typically the other aspect at the time of shape | molding in a U shape Part 1 The figure which shows typically the other mode at the time of shape | molding in a U shape Part 2 The figure which shows typically the aspect which attached the coil | winding to the wound iron core The figure which shows typically the other aspect which attached the coil | winding to the wound iron core Part 1 The figure 2 which shows typically the other aspect which attached the coil | winding to the wound iron core. The figure which shows a part of flow of the manufacturing process of the wound iron core by 2nd Embodiment. The figure which shows the aspect which anneals a wound iron core typically

Hereinafter, a plurality of embodiments will be described with reference to the drawings. In addition, the same code | symbol is attached | subjected and demonstrated to the site | part substantially common in each embodiment.
(First embodiment)
Hereinafter, the first embodiment will be described with reference to FIGS. 1 to 9.

  As shown in FIG. 1, the wound iron core 1 is formed in a ring shape as a whole by laminating a plurality of iron-based amorphous materials (hereinafter referred to as amorphous ribbons 2) formed in a ribbon shape. The wound iron core 1 is formed in an annular shape by attaching two iron core pieces 3 that are generally U-shaped. Each iron core piece 3 is formed with a plurality of concave and convex shapes on each joint surface 3a, here a plurality of triangular shapes in a side view, and the concave and convex shapes are designed to mesh with each other. The wound core 1 is finally mounted with a winding 4 and is used, for example, as a transformer core.

  Now, the amorphous ribbon 2 is formed in a ribbon shape by rapidly cooling the melted material. The amorphous ribbon 2 has elasticity before being annealed, and can be formed relatively easily and easily. On the other hand, since the tenacity decreases after annealing, the amorphous ribbon 2 can be handled so as not to break. Attention is required. Speaking of the manufacturing process, it is necessary to pay close attention to the machine or the like when the laminated amorphous ribbon 2 is formed or when the laminated ribbon is transferred.

Therefore, in the present embodiment, a manufacturing method described below is employed in order to facilitate handling during manufacturing.
FIG. 2 shows a method for manufacturing the wound core 1 according to this embodiment, together with a partial flow of the manufacturing process. In the manufacturing process of the wound core 1, first, the amorphous ribbon 2 is cut into a predetermined length (S1). This step S1 corresponds to a cutting step. As shown in FIG. 3, the amorphous ribbon 2 is supplied in a state of being wound in a coil shape called a hoop 10. The hoop 10 is rotatably held by a holding spool (not shown). In the cutting step, the amorphous ribbon 2 unwound from the hoop 10 is cut into a predetermined length by the cutting tool 11.

  In this embodiment, the amorphous ribbon 2 is cut in a state where a plurality of, for example, two unwound pieces from two hoops 10 are stacked. For this reason, the amorphous ribbon 2 of this embodiment has a thickness (D × X) obtained by multiplying the thickness (D) when unwound from one hoop 10 by the number (X) of the hoops 10. In general, D is approximately several tens of μm. Moreover, in the cut | disconnected state, the amorphous ribbon 2 is formed in the thin flat form of predetermined length.

  Subsequently, as shown in FIG. 1, the cut amorphous ribbons 2 are stacked in a predetermined arrangement (S2). This step S2 corresponds to a lamination step. Specifically, as shown in FIG. 4, the amorphous ribbon 2 is laminated with the positions of the end portions (both left and right sides in the drawing) being different so as to form the above-described uneven shape.

  Subsequently, as shown in FIG. 1, the laminated amorphous ribbon 2 is formed into a U-shape (S3). The step S3 corresponds to a U-shaped forming step. Specifically, as shown in FIG. 4, while holding the laminated amorphous ribbon 2 with the winding mold 12 from the top, the end protruding from the winding mold 12 is bent upward, so that the opening 3b is formed upward in the figure. An iron core piece 3 having a substantially U-shape and an uneven surface on the joining surface 3a is formed.

At this time, since the amorphous ribbon 2 has not been annealed yet, it has a tenacity, so it can be easily formed into a U-shape and has a low risk of breakage. Can do.
In addition, the winding mold 12 has an angle formed by a bottom surface side in contact with the amorphous ribbon 2 and a side surface side rising from the bottom surface side of approximately 90 degrees, and a corner portion is formed in a curved surface shape. Therefore, the iron core piece 3 formed in a U-shape also has a curved surface with a corner portion (R) of approximately 90 degrees.

  At this time, the shape of the wound core 1 is not limited to that shown in FIG. This is because the transformer may generate excitation vibration during operation, and thus the shape of the wound core 1 may be devised. More specifically, as shown in FIG. 5, the corner 12 is a so-called C-plane processed, that is, a winding mold 12 having a linear portion having an angle of approximately 45 degrees from the bottom surface to the side surface. Is used, the corner (R) of the core piece 3 in a U-shaped state can be formed in a linear shape of approximately 45 degrees. In this case, the angle formed by the pair of left and right corners is approximately 135 degrees.

  Even when such a straight corner portion is formed, that is, when the corner portion (R) of the wound iron core 1 is subjected to a clear bending process, before the amorphous ribbon 2 is annealed as described above. Since the bending process is performed on the amorphous ribbon 2, the risk of the amorphous ribbon 2 being damaged can be reduced. That is, the molding operation can be easily performed. Note that the corner (R) may be at an angle other than 90 degrees or 45 degrees.

  Moreover, an above-described lamination process (S2) and U-shaped shaping | molding process (S3) can be performed simultaneously. Specifically, as shown in FIG. 6, lamination and molding can be performed simultaneously by laminating the amorphous ribbon 2 above the winding mold 12 and lowering the end portion by its own weight. In this case, the joining surface 3a of the iron core piece 3 can be laminated and molded so as to have a flat shape instead of an uneven shape.

  Subsequently, as shown in FIG. 1, the amorphous ribbon 2 is annealed in a state of being formed in a U shape (S4). This S4 corresponds to an annealing process. In this case, annealing may be performed using a so-called annealing furnace, or excitation annealing for generating magnetic flux in the amorphous ribbon 2 using a coil or the like may be performed.

  Thereafter, the winding 4 is mounted (S5), and the U-shaped opening 3b is closed and formed into an annular shape (S6). S5 corresponds to a winding mounting process, and S6 corresponds to an annular forming process. In this annular forming step, as shown in FIG. 7, the two iron core pieces 3 are combined with each other with their joint surfaces 3a, and the opening 3b is closed to form an annular shape.

  In this way, the wound core 1 in which the amorphous ribbon 2 is laminated in an annular shape is manufactured. At this time, as shown in FIG. 8, the wound core 1 formed in an annular shape by closing the opening 3 b can also be manufactured by attaching the joint surfaces 3 a of one core piece 3 together. Moreover, as shown in FIG. 9, the winding core 1 in which the joining surface 3a was located in the center can also be manufactured by combining the core pieces 3 having the joining surface 3a formed in a flat shape. Moreover, the core piece 3 manufactured in the mode shown in FIG. 4 and FIG. 5 and the core piece 3 manufactured in the mode shown in FIG. Moreover, the wound core 1 can also be manufactured by combining the core piece 3 manufactured in the mode shown in FIG. 4 or 5 and the core piece 3 manufactured in the mode shown in FIG.

According to the embodiment described above, the following effects can be obtained.
In the manufacturing method of the wound core 1 of the embodiment, the amorphous ribbon 2 cut into a predetermined length is laminated and formed into a U shape, and the amorphous ribbon 2 is annealed and annealed in a state of being formed into the U shape. The winding core 1 is manufactured by closing the opening 3b of the ribbon 2 and forming it in an annular shape.

  Thereby, compared with the method of laminating and forming the flat amorphous ribbon 2 after annealing, the risk of the amorphous ribbon 2 being damaged when forming can be greatly reduced.

  Further, since the amorphous ribbon 2 formed in an annular shape is annealed, the opening 3b is formed from the beginning because it is formed in a U shape compared to a method of cutting a part in order to form an opening. The possibility of damaging the wound core 1 at the time of cutting and after cutting can be eliminated, and the work of forming the opening is not required, and the workability can be improved.

Further, since the risk of damage to the amorphous ribbon 2 can be reduced, the occurrence of defective products that must be damaged and discarded can be reduced, and productivity can be improved.
Therefore, handling at the time of manufacturing the wound core 1 can be facilitated.

  Moreover, in the manufacturing method of the wound iron core 1 of embodiment, the amorphous ribbon 2 is cut | disconnected by predetermined length in the state which piled up what was unwound from the several hoop 10. FIG. As described above, a typical amorphous ribbon 2 has a thickness of about several tens of μm, and when forming the wound core 1, it is necessary to stack a very large number of amorphous ribbons 2.

  Therefore, by laminating a plurality of sheets at the time of cutting, that is, at a stage where the work by the machine is possible, and laminating the amorphous ribbon 2 having an increased apparent thickness, the time required for the laminating work is increased in simple calculation. It can be reduced to 1 / (X). Thereby, the time required for production can be greatly shortened, and productivity can be improved.

  Moreover, in the manufacturing method of the wound core 1 of embodiment, when shape | molding the amorphous ribbon 2 in a U shape, at least 1 corner | angular part is shape | molded in a curved surface shape. As a result, it is possible to take measures against excitation vibration that occurs during operation of the transformer. Moreover, since the process of shape | molding in U shape is performed before annealing, the possibility that the amorphous ribbon 2 may be damaged during shaping | molding can be reduced.

  Moreover, in the manufacturing method of the wound iron core 1 of embodiment, when shape | molding the amorphous ribbon 2 in U shape, at least 1 corner | angular part is shape | molded linearly. As a result, it is possible to take measures against excitation vibration that occurs during operation of the transformer. In addition, since the process of forming a U-shape is performed before annealing, there is a risk that the amorphous ribbon 2 may be damaged during the forming even when a clear bending process is performed when forming the corners in a straight line. Can be reduced. In this case, the corner of one iron core piece 3 can be formed linearly as shown in FIG. 5, and the corner on the side of the opening 3b can be formed into a curved surface when closing the opening 3b.

(Second Embodiment)
Hereinafter, the second embodiment will be described with reference to FIGS. 10 and 11. In the second embodiment, the process order is different from that of the first embodiment. In addition, the same step number is attached | subjected and demonstrated to the process which is common in the process of 1st Embodiment.

  FIG. 10 shows the flow of the manufacturing process in this embodiment. In this manufacturing process, first, similarly to the first embodiment, the amorphous ribbon 2 is cut into a predetermined length (S1), laminated (S2), and then formed into a U-shape (S3). At this time, similarly to the first embodiment, the amorphous ribbon 2 is unwound from a plurality of hoops 10 and cut into a predetermined length in a stacked state, or at least one corner is formed into a curved shape. The at least one corner can be formed linearly. Further, lamination and molding can be performed simultaneously.

  Subsequently, the heat insulating material 15 is attached to the amorphous ribbon 2 (S10). This S10 corresponds to a heat insulating material mounting step. In this heat insulating material mounting step, as shown in FIG. 11, the heat insulating material 15 is mounted between the inner periphery of the winding 4 and the surface of the core piece 3 at least in the range where the winding 4 is mounted.

  Subsequently, as shown in FIG. 10, the winding 4 is attached to the portion where the heat insulating material 15 is attached (S5). Note that the order of the heat insulating material mounting step (S10) and the winding mounting step (S5) can be interchanged and can be performed simultaneously.

  Subsequently, the opening 3b of the U-shaped iron core piece 3 is closed and molded into an annular shape (S6). In this case, similarly to the first embodiment, two U-shaped core pieces 3 can be combined to close the opening 3b and be formed into an annular shape, and the opening 3b of one core piece 3 can be closed. It can be molded in an annular shape.

  And this winding iron core 1 is arrange | positioned in the vacuum furnace 20 which implement | achieves a vacuum environment, and it anneals in the state by which the coil | winding 4 was mounted | worn and was shape | molded by the ring (S4). At this time, by applying a high frequency voltage (E) between the input terminal 4 a and the output terminal 4 b of the winding 4, magnetic flux is passed through the amorphous ribbon 2 for excitation annealing. That is, in the present embodiment, the amorphous ribbon 2, that is, the iron core piece 3 in a state where the opening 3 b is closed and formed into a final annular shape is annealed.

  In this way, the amorphous ribbon 2 cut to a predetermined length is laminated and formed into a U-shape, and the winding 4 is attached to the amorphous ribbon 2 in the formed state, and the opening 3b of the amorphous ribbon 2 is closed. Even if the amorphous ribbon 2 is annealed in a state of being formed into an annular shape, the risk of the amorphous ribbon 2 being damaged during the molding can be greatly reduced, productivity can be improved, and the wound core 1 can be manufactured. The effect similar to 1st Embodiment can be acquired, such as being easy to handle.

  Moreover, in the manufacturing method of the wound core 1 of embodiment, since it anneals after closing the opening part 3b, when closing the opening part 3b and shape | molding in cyclic | annular form, the amorphous ribbon 2 has a softness | flexibility. The possibility of damage can be eliminated.

  Moreover, in the manufacturing method of the wound core 1 of the embodiment, the winding 4 is attached to the amorphous ribbon 2 in a state where the heat insulating material 15 is disposed between the amorphous ribbon 2 and the winding 4, The amorphous ribbon 2 is installed in a vacuum environment with the heat insulating material 15 and the winding 4 attached, and the amorphous ribbon 2 is annealed by applying a high frequency voltage (E) to the winding 4 in a state of being installed in a vacuum environment. . That is, annealing is performed in the final wound core 1 state.

  Thereby, since it becomes unnecessary to shape | mold or process the wound iron core 1 itself after annealing, the possibility of damaging the amorphous ribbon 2 can be greatly reduced.

  Similarly, in the wound core 1 that is formed in an annular shape by closing the opening 3b by attaching the joint surface 3a of one iron core piece 3 as shown in FIG. 4 can be used to anneal the amorphous ribbon 2. Further, a wound iron core 1 using an amorphous ribbon 2 cut into a predetermined length in a state where unrolled ones from a plurality of hoops 10 are stacked, a wound iron core 1 in which at least one corner is formed into a curved shape, and at least The manufacturing method of the present embodiment can also be applied to a wound core 1 in which one corner is linearly formed.

(Other embodiments)
In the embodiment, an example is shown in which two amorphous ribbons 2 are cut and stacked. However, three or more amorphous ribbons 2 can be cut and used. Moreover, what cut | disconnected the one amorphous ribbon 2 without overlapping can also be used.

  Although several embodiments of the present invention have been described, these embodiments are presented by way of example and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

  In the drawings, 1 is a wound iron core, 2 is an amorphous ribbon (amorphous material), 3 is an iron core piece (wound iron core), 3b is an opening, 4 is a winding, 15 is a heat insulating material, and 20 is a vacuum furnace.

Claims (6)

A method of manufacturing a wound core formed by winding a ribbon-shaped amorphous material,
The amorphous material cut to a predetermined length is laminated and formed into a U shape,
Annealing the amorphous material in a U-shaped state,
A method of manufacturing a wound iron core, wherein the opening of the annealed amorphous material is closed and formed into an annular shape. A method of manufacturing a wound core formed by winding a ribbon-shaped amorphous material,
The amorphous material cut to a predetermined length is laminated and formed into a U shape,
Mount the winding on the amorphous material in the molded state,
Close the opening of the amorphous material and shape it into a ring,
A method for manufacturing a wound core, comprising annealing the amorphous material in a state of being formed into an annular shape. At the site where the winding is mounted on the amorphous material, the winding is mounted in a state where a heat insulating material is disposed between the winding and the winding,
3. The amorphous material is annealed by installing the amorphous material in a vacuum environment in a state where the heat insulating material and the winding are mounted, and applying a high frequency voltage to the winding. Method for manufacturing a wound iron core.   The method for manufacturing a wound iron core according to any one of claims 1 to 3, wherein the amorphous material is cut into a predetermined length in a state in which those unwound from a plurality of hoops are stacked.   The method for manufacturing a wound core according to any one of claims 1 to 4, wherein when forming the amorphous material, at least one corner is formed into a curved surface.   The method for manufacturing a wound core according to any one of claims 1 to 5, wherein when forming the amorphous material, at least one corner is linearly formed.

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