JP2574662B2 - Method and apparatus for inserting core of transformer - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for inserting a core into a window of a coil when assembling a transformer, and to an apparatus for inserting a core used for carrying out the method.

[0002]

2. Description of the Related Art As shown in FIG. 6, a transformer using a wound iron core is one in which coils W and W 'are fitted to a rectangular transformer iron Co having a wound iron core structure. Is 1
It comprises a pair of legs X, X 'and a pair of yoke portions Y, Y' connecting between both ends of these legs. Coil W,
W 'is a concentrically wound primary coil and a secondary coil, and these coils are fitted on the legs X and X' of the transformer core, respectively.

In order to improve the occupation rate of the core in the coil window by making the cross-sectional shape of the iron core close to the cross-sectional shape of the coil window, the transformer core Co generally has a width dimension as shown in FIG. It has a structure in which a plurality of different rectangular cores are combined. In the illustrated example, a total of three winding cores C2 having a large width and a large cross-sectional area, and winding cores C1 and C3 having a small width arranged along the inner and outer peripheral sides of the core, respectively. A transformer core Co is constituted by the wound core.

The wound iron cores C1 to C3 are formed by laminating a number of strip-shaped silicon steel sheets cut to a predetermined size, press-forming them in a rectangular shape, and then annealing them. The legs X and X 'of the transformer iron core are provided. And a pair of legs x, x 'and a yoke Y,
The yoke has yoke portions y and y 'constituting Y', and both ends of the steel plate are lap-joined or butt-joined at one yoke portion y. Whichever joining method you use,
In order to reduce the magnetic resistance of the joint, the joints of the adjacent steel plates are arranged so as to be shifted from each other in the longitudinal direction of the yoke. Therefore, in this type of transformer core, as shown in FIG. 8, one yoke portion y of each wound core is divided into a first yoke half y1 and a second yoke half y2, The leading ends of the first yoke half y1 and the second yoke half y2 are a step-like inclined surface J1 facing outward and a step-like inclined surface J2 facing inside, respectively. The surfaces J1 and J2 are overlapped to form a joint J.

FIG. 8 shows the structure of the joint when lap joining is employed.
The portion s forming one step is formed of one silicon steel sheet or a laminate of a plurality of silicon steel sheets.

[0006] When assembling the above transformer, the coil is inserted into the window of the coil in order from the wound core having the smaller diameter. When inserting each core into the window of the coil, if necessary (to facilitate handling), further divide the core into a plurality of unit cores, and join them in order from the unit core with the smaller diameter. Is opened, and its legs are inserted into the windows of the pair of coils W, W. Each unit wound iron core is generally constituted by a laminate of several to about ten steel sheets. Winding core C1 to C3
Has a similar shape to the wound cores C1 to C3, the same names as those of the wound cores C1 to C3 will be used hereinafter for the names of the respective parts of the unit wound cores and the symbols indicating the respective parts. .

[0007]

Conventionally, when assembling the above-mentioned transformer, the work of inserting the wound iron cores C1 to C3 into the window of the coil has all been performed manually, resulting in poor assembly workability. There was a problem.

[0008] Further, if all the work of inserting the wound iron core is performed manually, there is a possibility that the quality of the transformer varies due to individual differences in the work.

SUMMARY OF THE INVENTION An object of the present invention is to provide a method of inserting a core of a transformer in which most of the work of inserting a wound core can be performed by using a machine, and an apparatus for inserting the core used for carrying out the method. It is in.

[0010]

According to the method of the present invention, one yoke portion y is divided into a first yoke half y1 and a second yoke half y2, and The ends of the iron halves and the second yoke halves are joined with a stepped inclined surface J1 facing outward and a stepped inclined surface J2 facing inside, respectively, to form a rectangular wound core forming a joint. This is a method of inserting into the window of the coil.

In the present invention, a pair of coils W and W '
And disposing the pair of legs x, x of the pair of wound cores in the vicinity of one end of the yoke side to displace outwardly. Opening the joint J, the first yoke half y1 and the second yoke half y
2 and the first yoke half y1 and the second yoke half of the wound core Cu having the joints opened with the ends of the pair of control bars 46 and 47 penetrating through the windows of the pair of coils. Contacting the leading end of the yoke half y2 to keep the joint open; and moving the wound core together with the control bars 46 and 47 to the coil side to cause the first yoke of the wound core to move. Inserting the vicinity of the distal ends of the half and the second yoke half into the windows of the pair of coils W, W ', and winding the wound core Cu together with the control bars 46, 47 around the coils W, W'. Axially moving the pair of legs of the wound core into the windows of the pair of coils; and the tip of the first half of the yoke and the second half y2 of the wound core. And removing the control bars 46 and 47 from the tip of.

By performing the above steps, a series of operations for inserting the leg of the wound core into the window of the coil can be mechanized.

In order to further mechanize the operation of rejoining the joined portion, first, the first step of removing the control bar is carried out in the step of removing the control bar.
After the control bar 46 is removed from the yoke half y1 and the joining auxiliary plate 84 is applied to the inclined surface J1 at the tip of the first yoke half, the control bar 46 is removed from the second yoke half. Remove the 47
Of the first half of the yoke is brought into contact with the inclined surface J1 of the first half of the yoke via the joining auxiliary plate 84. Next, the vicinity of the rear ends of the first yoke half y1 and the second yoke half y2 of the wound iron core are pressed toward their respective tip ends, and the inclined surface of the first yoke half and the second yoke half Adjusting the positions of the two inclined surfaces by sliding the inclined surfaces of the yoke half along the joining auxiliary plate, and removing the joining auxiliary plate 84 from the joint to remove the tip of the second yoke half. Superposing the inclined surface on the inclined surface at the tip of the first yoke half and closing the joint.

The iron core inserting device of the present invention has one yoke portion y.
Is divided into a first yoke half y1 and a second yoke half y2, and the tips of the first yoke half and the second yoke half respectively face outward. This device inserts a pair of legs of a rectangular wound iron core that is joined by a stepped inclined surface J1 and an inwardly directed stepped inclined surface J2 to form a joint J into a pair of coil windows. .

The apparatus of the present invention comprises a coil holding device 5 for arranging and holding a pair of coils W and W 'in a state where their respective winding axes are parallel to each other, and a joining portion opening for opening a joining portion of the wound core. And an apparatus 30. Joint expansion device 30
Represents a pair of coils W and W ′ held by the coil holding device.
Is provided so as to be able to move between the operating position and the retracted position on one side in the direction along the winding axis of the winding core. A pair of restraining devices 20 to 25 for restraining the vicinity of the end on the iron side,
A restraint that displaces the pair of restraints so that the joint of one yoke y is opened and the tip of the first yoke half y1 is separated from the tip of the second yoke half y2. Tool drive mechanism 33,3
4 is provided.

The joint expanding device is moved to the operating position and the retracted position by the expanding device moving mechanism 35, and is moved in the direction of the winding axis of the coil. A yoke support 102 is provided to support the other yoke y 'of the wound core Cu with the joint expanding device retracted to the retracted position, and the yoke support includes coils W and W'. Is provided so as to be movable in the winding axis direction.

In the apparatus of the present invention, the coil holding device 5
And a pair of control bars 46, 47 extending parallel to the respective winding axes of the pair of coils held by the pair. The control bars 46 and 47 are supported by a control bar support device on the other side in the direction along the winding axis of the pair of coils, and are controlled by the control bar moving mechanisms 44 and 45 to the winding axes of the pair of coils. It is reciprocated in the direction along.

According to the present invention, there is further provided a control device for operating the above-described units in a predetermined order. This control device performs an operation of opening a joint portion of one yoke portion of the wound core,
The pair of control bars are moved toward the core through the windows of the pair of coils, and the tips of the pair of control bars are moved to the first side of the core.
The inner and outer ends of the yoke half and the second yoke half are moved in the direction of the winding axis of the coil together with the joint expanding device and the control bar. The operation of inserting the vicinity of the distal ends of the first half of the yoke and the second half of the second yoke into the windows of the pair of coils and restraining the other yoke of the wound core with the yoke supporter Moving the joint expanding device to the retracted position by releasing the restraint by the tool, and a pair of control bars and a yoke until the pair of legs of the wound core are inserted into the windows of the pair of coils. An operation of moving the support and the winding core along the winding axis of the coil;
Removing one control bar from the end of the first yoke half after inserting the pair of legs into the window of the pair of coils;
The joint expanding device 30, the control bar moving mechanisms 44 and 45, and the expanding device moving mechanism 35 are controlled so as to perform the operation of removing the other control bar from the end of the yoke half.

In the present invention, a pair of legs is inserted into the window of the pair of coils to mechanize the operation of rejoining the joint of the wound core inserted into the window of the coil,
Between the operating position where one of the control bars covers the inclined surface J1 of the tip of the first yoke half y1 of the wound core Cu from which the one of the control bars has been removed, and the retracted position where the movement of the control bars 46 and 47 is not hindered. Auxiliary joining plate 84 provided so as to be able to move the joint auxiliary plate 84, a joining auxiliary plate moving mechanism 85 for moving the joining auxiliary plate 84 between the operating position and the retreat position, and a pair of coil windows having a pair of legs. Yoke half pressing mechanisms 75 and 76 for pressing the rear ends of the first yoke half and the second yoke half of the wound iron core inserted toward the respective tip ends, and the wound iron core Cu. And joint holding mechanisms 51 and 52 for holding the joint of one of the yoke sections from the outside.

In this case, the control device operates to move the joining auxiliary plate 84 to the operating position after removing one of the control bars 46 from the end of the first yoke half y1 of the wound core, and the other control bar. Is removed from the tip of the second yoke half y2 of the wound core, and then the first yoke half and the second yoke half of the yoke are provided with the joining auxiliary plate interposed between the joints. Further, the joining auxiliary plate is moved so as to perform an operation of pressing the rear end of the portion toward the front end side and an operation of pressing the joining portion from the outside after removing the joining auxiliary plate from the joining portion of the wound core. The mechanism, the yoke half pressing mechanism and the joint pressing mechanism are controlled.

[0021]

As described above, the first part of the wound core having the joint opened is described above.
After the ends of the control bar are brought into contact with the ends of the yoke halves and the end of the second yoke half, respectively, and the joint is kept open, the first yoke half of the wound core and At least a part of the second yoke half is inserted into the window of the coil, and the control bar holds one yoke side of the core and can move the other yoke of the core. When the control bar is moved together with the winding core while being supported by the yoke support so that the pair of legs of the winding core are inserted into the windows of the pair of coils,
The insertion of the wound core can be smoothly performed by a machine. In this case, since the wound core is inserted into the window of the coil while being guided by the control bar, the core can be inserted without damaging the coil and the core.

After the pair of legs of the wound core are inserted into the window of the coil, one of the control bars is connected to the first of the yoke.
When the first half of the yoke is removed from the half of the yoke, the first half of the yoke is released from the constraint and almost returns to the state before the joint was opened. Next, when the other control bar is removed from the second half of the first yoke, the second half of the yoke is released from the restraint, and the tip of the second half of the yoke becomes the tip of the first half of the yoke. Overlap on the part. Here, by adjusting the degree of overlap between the first half of the yoke and the second half of the yoke, it is possible to easily rejoin the yoke.

Further, as described above, after one of the control bars is removed from the first half of the yoke of the core wound with the pair of legs inserted into the window of the core, the first yoke is removed. The joining auxiliary plate is applied to the inclined surface at the tip of the half, and after the control bar is removed from the second yoke half of the wound core, the first yoke half and the second yoke half are removed. When the rear ends of the first yoke half and the second yoke half are pressed toward the respective tip ends in a state where the joining auxiliary plate is interposed between the joining portions of the portions, the first Since the inclined surface at the tip of the yoke half and the inclined surface at the tip of the second yoke half can be slid along the joining auxiliary plate, respectively, the positions of the two inclined surfaces can be easily adjusted. The rejoining of the joint of the iron core can be easily performed.

[0024]

1 and 2 show the overall construction of an embodiment of an iron core inserting apparatus according to the present invention. FIG. 1 is a plan view and FIG.
Is a front view. In these figures, reference numeral 1 (see FIG. 2) denotes a frame of the apparatus. A pair of setting rails 2 is fixed on the upper surface of the frame 1, and a coil mount 3 is supported on the rails 2 via wheels. I have. Coil mount 3
Can be moved along a rail 2 between a work position shown in the figure and a product take-out position located on the near side in FIG.

A pair of coils W, W
′ Are arranged side by side with their winding axes parallel to each other in a horizontal direction, and a coil holder 3 and a coil holder 4 constitute a coil holding device 5.

A motor 6 is fixed to one end of the frame 1. A ball screw 7 extending parallel to the winding axis direction of the coils W and W 'is connected to an output shaft of the motor. It is screwed into a ball nut provided on the base 8. The core moving table 8 is guided by a guide mechanism (not shown) so as to be movable only in the winding axis direction of the coils W and W ′. It reciprocates in the winding axis direction.

An air cylinder 9 for vertically driving the piston rod 9a projecting upward is fixed to the iron core moving table 8, and an iron core clamp table 10 is fixed to the upper end of the piston rod of the air cylinder 9. A motor 11 is mounted on the iron core clamp base 10, and a ball screw 12 extending in the direction of the winding axis of the coils W and W 'is connected to the output shaft of the motor. The ball screw 12 is screwed into a ball nut provided on a clamp base 13 movably supported only in the direction of the winding axis of the coil by a guide mechanism (not shown). It is designed to be driven back and forth in the winding axis direction. A clamp 15 driven by an air cylinder 14 is attached to the clamp base 13.
A motor 16 is also attached to the iron core clamp base 10, and a ball screw 17 extending in a direction orthogonal to the winding axis direction of the coil is connected to an output shaft of the motor. A right screw is provided in one half of the ball screw 17 and a left screw is provided in the other half, and ball nuts provided on the movable pieces 18 and 19 are screwed to the right screw and the left screw, respectively. . The movable pieces 18 and 19 are supported by a guide mechanism (not shown) so as to be movable only in the axial direction of the ball screw 17.
The movable pieces 18 and 19 are driven in directions that approach each other and move away from each other.

First movable rollers 18 and 19 are provided with first opening rollers 20 and 21 having rotating shafts extending in the vertical direction, respectively. The rotating shafts of the opening rollers 20 and 21 have one ends of opening arms 22 and 23 attached thereto. Is connected. At the other ends of the opening arms 22 and 23, second opening rollers 24 and 25 whose rotation axes are directed in the vertical direction are attached.
The movable pieces 18 and 19 have servo motors 26 and 2 respectively.
7 are attached, and rotation of these servo motors is controlled by the opening belts 20, 21 via timing belts 28, 29.
Is transmitted to the rotating shaft. Therefore, the servo motor 26,
With the rotation of 27, the opening arms 22 and 23 rotate in directions opposite to each other, and the second opening rollers 24 and 25 are displaced in a direction approaching each other and in a direction separating from each other.

In this example, an iron core clamp base 10, a clamp base 13 driven by a motor 11 via a ball screw 12, a clamp device 15 driven by an air cylinder 14, and a motor 16 driven by a ball screw 17 Movable tops 18, 19, and opening rollers 20, 21, 24, 2 attached to these movable tops.
5, opening arms 22, 23, and servo motors 26, 2
7 and the timing belts 28 and 29 constitute a joint expanding device 30.

In FIG. 1, Cu indicates a unit core inserted into the windows of the coils W and W ', and C indicates a core already inserted into the windows of the coils. The unit core Cu inserted into the window of the coil clamps the yoke y 'having no joint by the clamp tool 15, and the yoke y having the joint of the pair of legs x and x'. It is arranged in a state where the vicinity of the end on the side is placed on the opening arms 22 and 23. In this state, the first opening rollers 20 and 21 face the outer surfaces of the legs x and x 'of the wound iron core Cu, respectively,
Open rollers 24 and 25 face the inner surfaces of the ends of the legs x and x '.

After the unit cores Cu are set as described above, the servo motors 26 and 27 are rotated in one direction.
The second opening rollers 24 and 25 rotate in a direction away from each other, and as shown in FIG.
4 and 25 abut on the inner surfaces of the legs x and x 'of the wound core Cu, and the first opening rollers 20 and 21 abut on the outer surfaces of the legs x and x' of the wound core. This makes the winding iron Cu
The vicinity of the end on the side of the yoke portion y is restricted. When the servo motors 26 and 27 are further rotated in this state, FIG.
As shown in (C), the ends of the leg portions x and x 'of the wound core Cu are bent outwardly, so that the first yoke half y1 and the second yoke half of the wound core are formed. y2 is moved away.

In this example, the opening rollers 20, 21 and 24, 25 of the unit core core Cu and the opening arms 22, 23 are used to close the vicinity of one end of the pair of legs of the core unit on the yoke side. A pair of restraints 31 and 32 for restraining each other are configured,
Servo motors 26 and 27 and timing belts 28 and 29
With this, the joint of one yoke of the wound core is opened to
Constraint driving mechanisms 33, 34 for displacing the restraints 31, 32 so as to separate the tip of the yoke half from the tip of the second yoke half.

The joint expanding device 30 is moved to an operating position shown in the figure and to a retracted position located below the position shown by the motor 6, the ball screw 7, the iron core moving base 8 and the air cylinder 9. An expansion device moving mechanism 35 for moving the expansion device 30 in the direction of the winding axis of the coils W and W 'is configured.

A ball screw 41 driven by a servomotor 40 is supported on the upper end of the other end of the frame 1.
Ball nuts provided on the movable pieces 42 and 43 are screwed to right and left screws provided on the ball screw 41, respectively. Therefore, the rotation of the servomotor 40 drives the movable pieces 42 and 43 in a direction approaching each other or in a direction away from each other.

The movable pieces 42 and 43 are provided with linear drive mechanisms 44 and 45 using a servo motor as a drive source, and output shafts 44a and 45 of these linear drive mechanisms.
a supports the rear ends of a pair of control bars 46 and 47 extending parallel to the winding axis of the pair of coils W and W '. The control bars 46 and 47 are reciprocated in the winding axis direction of the coils by the linear drive mechanisms 44 and 45, penetrate through the windows of the coils W and W ', and are joined as shown in FIG. Iron core C whose joint is opened by the part expansion device
u, between the first yoke half y1 and the second yoke half y2, and from the window of the coils W and W 'to be separated from the window. Displaced between the position (the position shown in FIG. 1).

In this example, a servo motor 40 and a movable piece 4 driven by the motor via a ball screw 41 are used.
The control bars 2 and 43 constitute a control bar supporting device that supports the control bars 46 and 47 at an adjustable interval, and the linear driving mechanisms 44 and 45 reciprocate the control bars 46 and 47 in the coil winding axis direction. A control bar moving mechanism is configured.

An air cylinder 51 is mounted on the other end of the frame 1 via a mounting member 50.
In this air cylinder, the axis of the piston rod is oriented in a direction parallel to the winding axis direction of the coils W and W ', and the piston rod is positioned at the center between the coils W and W'. The joint part holding plate 52 is attached to the distal end of the piston rod. Presser plate 52
1 is a retracted position shown by a solid line in FIG. 1 driven by the air cylinder 51, and an iron core holding position abutting on a joint of the wound core inserted into the window of the coil as shown by a chain line in FIG. Can be displaced between. The air cylinder 52 constitutes a joint holding mechanism for pressing the joint of one yoke of the wound core from the outside.

An air cylinder 53 is further supported on the other end of the frame 1, and a welding torch 54 is attached to a tip of a piston rod of the air cylinder 53. The welding torch 54 is driven by the air cylinder 53 to move between a welding position where the welding portion approaches the joint portion of the wound core inserted into the window portion of the coil and welds the joining portion, and a retracted position away from the joining portion. Can be displaced between.

The frame 1 further supports a welding earth electrode 56 via an air cylinder 55. The earth electrode is driven by the air cylinder 55 to come into contact with the winding core inserted into the coil and the winding core. From the position away from the camera.

The frame 1 is also moved in a direction perpendicular to the plane of FIG. 2 (a direction perpendicular to the winding axis direction of the coils W and W ') by a linear drive mechanism using a motor 57 as a drive source. A movable block 58 is supported, and an air cylinder 59 is supported on the movable block. A vibration sensor 60 is attached to the tip of the piston rod of the air cylinder 59.
And a roller 61 are attached, and an air cylinder 59,
The vibration sensor 60 and the roller 61 constitute a joint confirmation and detection device 62 that is inserted into the window of the coil and confirms the joint of the wound core to which the yoke y is rejoined.

The joint confirmation detecting device is used in a state where the air cylinder 59 is driven to bring the roller 61 into contact with the yoke 7 of the wound core where the joint is rejoined. In a state where the roller 61 is in contact with the joint of the wound core, as shown in FIG. 5, a state in which the elastic wire-shaped probe 60a made of a piano wire or the like provided on the vibration sensor 60 is bent. With this, it comes into contact with the outer peripheral surface of the yoke portion y of the wound core. In this state, when the motor 57 is driven to move the movable block 58 in a direction perpendicular to the winding axis direction of the coil, the probe 6
The tip of Oa slides on the outer peripheral surface of the yoke part y.
Now, as shown in FIG. 5, the distal end of the probe 60a is moved from the second yoke half y2 side to the first outer peripheral surface of the joint as shown by the arrow in FIG.
Is moved toward the yoke half y1 side, the tip of the probe 60a falls from the step Ja formed on the outer peripheral surface of the joint J during the movement and vibrates. In FIG. 5, when the vibration sensor 60 is moved from the first yoke half y1 side to the second yoke half y2 side, the tip of the probe 60a of the vibration sensor Although the probe rides on the step Ja, the probe 60a does not vibrate. The vibration sensor 60 detects a vibration when the vibration sensor is displaced in a specific direction (in the example of FIG. 5, from the second yoke half y2 side to the first yoke half y1 side). It is detected that the joint of the wound core is correctly formed.

On the frame 1, an air cylinder 65 is also provided.
And 66 are attached, and the piston rods 65a and 66a of these air cylinders are attached near the corners (first yoke half y1) on both sides of one yoke y of the core C inserted into the window of the coil. And the second yoke half y2). Movable blocks 67 and 68 are attached to the distal ends of the piston rods 65a and 66a, and the first and second yoke halves y1 and y1 of the core C are respectively attached to the distal ends of these movable blocks. Ironing rollers 69 and 70 are attached to contact the rear end of the portion y2. Air motors 71 and 72 are also attached to the movable blocks 67 and 68, and the outputs of these air motors are transmitted to the rotating shafts of the ironing rollers 69 and 70 via timing belts 73 and 74. The core C inserted into the window of the coil W, W 'by the air cylinders 65, 66, the movable blocks 67, 68, the ironing rollers 69, 70, the air motors 71, 72, and the timing belts 73, 74. The yoke half pressing mechanisms 75 and 76 are configured to press the rear ends of the first yoke half y1 and the second yoke half y2 toward their respective tip ends.

The frame 1 also supports a movable piece 82 that is reciprocated in the direction of the winding axis of the coil by a ball screw 81 connected to the output shaft of a servomotor 80. An air cylinder 83 is mounted on the movable piece 82. Have been. The air cylinder 83 is provided so that its piston rod extends in a direction orthogonal to the direction of the winding axis of the coil, and a joining auxiliary plate 84 is attached to the tip of the piston rod. The joining auxiliary plate 84 extends in the longitudinal direction of the yoke portion y having the joint portion of the wound core C inserted into the coil, and its tip end is stepwise inclined at the tip end of the first yoke half y1. It is formed in a curved shape substantially along the surface J1.

Motor 80, ball screw 81 and movable piece 8
2 and the air cylinder 83, the joining auxiliary plate moving mechanism 8
5 is constituted, and the joining auxiliary plate 84 is
Is in the state of covering the inclined surface J1 of the tip of the first yoke half y1 of the wound core C inserted in the window of the coil, and the retracted position which does not hinder the movement of the control bars 46 and 47. It can be moved between.

One end of the frame 1 has a servo motor 9
A ball screw 91 driven by the ball screw 0 is attached, and ball nuts provided on the movable pieces 92 and 93 are screwed to right and left screws provided on the ball screw 91, respectively. The movable pieces 92 and 93 are provided with linear drive mechanisms 94 and 95 using a servo motor as a drive source. The output shafts 94a and 95a of the linear drive mechanisms are parallel to the winding axis direction of the coils W and W '. Insertion support bar 9 extending to
The rear ends of 6 and 97 are connected. Insertion assistance bar 9
The retracted positions 6 and 97 are driven by the linear drive mechanisms 94 and 95 so that the respective distal ends are separated from the core Cu held by the joint expanding device as shown in FIG. 4 (A) is displaced. As shown in FIG. 3E, the insertion assist bars 96 and 97 come into contact with the outer surfaces on the rear end side of the yoke halves y1 and y2 of the wound iron core Cu whose joint is opened as shown in FIG. Then, while maintaining this state, it moves to the forward position shown in FIG. The distance between the insertion assist bars 96 and 97 is adjusted by a servo motor 90.

In this example, the insertion assist bars 96, 9 are formed by the servomotor 90, the ball screw 91, and the movable piece 94.
An insertion assist bar supporting device that supports the distance of the insertion assist bar 7 is configured, and an insertion assist bar moving mechanism that reciprocates the insertion assist bar in the direction of the authority axis of the coil by the linear drive mechanisms 94 and 95 is configured.

The frame 1 also includes insertion assist bars 96,
97, a servo motor 100 is mounted, and a yoke support 10 made of an electromagnet is provided at the tip of the output shaft of a linear drive mechanism 101 driven by the servo motor.
2 are installed.

The frame 1 has a vibration applying device 105 for applying vibration to the vicinity of the corners on both sides of the yoke portion y 'which does not have the joint portion of the wound core C inserted into the window portion of the coils W and W'.
And 106 are attached. These vibration applying devices consist of an electromagnetic vibrator,
Is attached to the tip of a support arm 108 rotatably supported by a pin 107. Support arm 1
08 is connected to a piston rod of an air cylinder 109 via a pin, and the support arm 108 is rotated by the air cylinder 109, so that the vibration applying devices 105 and 106 It is possible to move between an operation position where it contacts the corner portions on both sides of y ′ and a retracted position where it is separated from the corner portions.

Next, a method of inserting the iron core using the above-described iron core inserting device will be described.

First, the coils W and W 'are set on the coil mount 3, and the coil mount 3 is moved along the setting rail 2 to the working position shown in FIG. In the present embodiment, the winding cores C1 to C3 constituting the transformer core are further divided into unit winding cores Cu made of several to about ten steel plates, and a series of unit winding cores are sequentially arranged in the windows of the coils W and W '. Assemble the iron core by inserting it into the part. FIG. 1 shows coils W, W
'Shows a state in which a predetermined number of unit wound cores have already been inserted into the window portion (a state in which the core is being assembled), and C shows an iron core in the course of assembly. In this state, the piston rod of the air cylinder 51 is in an extended state,
The joint holding plate 52 at the tip abuts on the joint of the iron core C as shown by the chain line in FIG. 1 to press the joint.

Next, as shown in FIGS. 1 and 3A, the unit wound iron core Cu inserted into the windows of the coils W and W 'has the legs x and x' on the open arms 22 and 23, respectively. With the opening rollers 20, 21 facing the outer surfaces of the legs x, x ',
The opening rollers 24 and 25 are opposed to the inner surfaces of the ends of the legs x and x 'on the yoke y side. Next, the servo motor 11
Is rotated to move the clamp base 13 to the fixed position toward the winding core Cu, and the air cylinder 14 is driven to clamp the yoke portion y 'of the winding core Cu by the clamp 15.
Next, the servo motors 26 and 27 are rotated to open the arm 2.
2 and 23 are rotated in a direction away from each other. As a result, as shown in FIG. 3B, the joint J of the wound iron core Cu is formed.
To displace the first yoke half y1 and the second yoke half y2 outward.

Then, the servo motor 16 is rotated to
Move the movable pieces 18 and 19 in a direction away from each other,
As shown in FIG. 3C, the legs x, x 'of the wound iron core Cu.
To the home position (the control bar 46, the distance between the tip of the first yoke half y1 and the tip of the second yoke half y2, will be described later).
(Until the interval at which 47 can be inserted).

Next, the linear drive mechanisms 44 and 45 using the servo motor as a drive source are driven to move the control bars 46 and 47 to the coil side. The distance between the control bars 46 and 47 is adjusted to be slightly larger than the width of the iron core C inserted in the window of the coils W and W '. Fig. 3 (D) through the window of W
As shown in the figure, the core is inserted between the first yoke half y1 and the second yoke half y2. In this case, the control bar 47 is connected to the control bar 4 in order to ensure that the tip of the yoke half y2 having the inwardly inclined surface J2 abuts on the control bar 47.
Displace more than 6.

Next, the servo motor 6 is rotated to move the iron core moving table 8 toward the coils W and W ', and at the same time, the linear driving mechanisms 44 and 45 are operated in synchronization with the movement of the iron core moving table 8. , The control bars 46 and 47 are retracted to the right in FIG. As a result, portions of the first and second yoke halves y1 and y2 of the wound core Cu having at least the inclined surfaces J1 and J2 are inserted into the windows of the coils W and W '.

Next, the servomotor 100 is driven to move the yoke support 102 toward the winding core Cu, and the electromagnets constituting the yoke support 102 are excited to attract the yoke y 'of the winding core Cu. Let it.

Next, the clamping of the yoke portion y 'by the clamp member 15 is released, the air cylinder 9 is driven to lower the iron core clamp base 10, and the joining portion expanding device 30 is moved to the winding core C.
Retreat to a position that does not interfere with u.

Thereafter, the servo motors of the linear drive mechanisms 94 and 95 are rotated to move the insertion assist bars 96 and 97 toward the winding core, and as shown in FIG. The ends are brought into contact with the side surfaces on the rear end side of the first yoke half y1 and the second yoke half y2 of the winding core, and the control bar and the insertion auxiliary bar are used to make the ends of the legs of the winding core. And hold it. The distance between the insertion assist bars 96 and 97 is adjusted in advance by the servomotor 90.

Next, the linear drive mechanisms 44, 45, 94, 9
5 and 101, the control bars 46 and 47, the insertion auxiliary bars 96 and 97, and the yoke support 102 are simultaneously moved rightward in FIG.
As shown in (A), the wound iron core Cu is inserted into the windows of the coils W and W '.

After the insertion assist bars 96 and 97 are retracted to the left in FIG. 1, the air cylinder 109 is driven in the state shown in FIG.
Are brought into contact with the corner portions on both sides of the yoke portion y 'of the wound core Cu, and the vibrator of the vibration applying device is operated to apply vibration to the wound core Cu. As a result, the corner portion of the wound iron core Cu and the corner portion of the already inserted core C are made to overlap well.

Here, a direct current is applied to each of the primary coils of the coils W and W 'to magnetize the iron core, thereby preventing the wrap of the iron core from shifting.

Next, the air cylinder 51 is operated to retract the joint holding plate 52 rightward in FIG. 1, and the control bar 46 is moved rightward to move the first yoke half y1 of the wound core Cu. Remove from the tip. At this time, the first yoke portion y1 of the wound iron core
Due to the restoring force of the wound core itself, the wound core substantially comes into contact with the yoke portion of the already inserted core C as shown in FIG.

After the control bar 46 is moved to remove it from the first yoke portion y1 of the wound core, the air cylinder 83 is driven to advance the joining auxiliary plate 84, and the joining auxiliary plate 84 is moved to the position shown in FIG.
As shown in (C), the first core half y1 of the wound core is brought into contact with or opposed to the inclined surface of the first yoke half y1. The position of the joining auxiliary plate 84 in the winding axis direction of the coil is adjusted in advance by the servomotor 80.

Next, the control bar 47 is moved rightward in FIG. 1 to remove the tip of the control bar from the tip of the second yoke portion y2 of the wound core. Thereby, the second yoke part y2
Is the iron core C already inserted, as shown in FIG.
And the inclined surface at the tip of the second yoke portion y2 faces or abuts the joining auxiliary plate 84.

Next, the ironing rollers 69 and 70 are advanced by driving the air cylinders 65 and 66, and the two ironing rollers 69 and 70 are moved to the first yoke half y1 and the second yoke half y2. The ironing rollers 69 and 70 are rotated in the counterclockwise direction and the clockwise direction in FIG. 1, respectively, by being brought into contact with the side surface on the rear end side and rotating the air motors 71 and 72. As a result, the first yoke portion y1 and the second yoke portion y2 are pushed toward the respective distal ends, and FIG.
As shown in (E), the overlapping portions of the respective inclined surfaces J1 and J2 are opposed to each other via the joining auxiliary plate 84, and the tightness of the wound core Cu is improved.

As described above, when the joining portion is rejoined with the joining auxiliary plate 84 interposed at the joining portion between the first yoke half y1 and the second yoke half y2, The uneven surfaces of the step-like inclined surfaces J1 and J2 of the first and second yoke halves interfere with each other to prevent mutual interference, so that the inclined surfaces of both yoke halves can be easily matched. Therefore, it is possible to mechanize the operation of rejoining the joint.

Next, the excitation of the coils W and W 'is turned off, the joining auxiliary plate 84 is extracted from the joining portion, and the ironing rollers 69 and 70 are rotated again, and the vibration applying device 10 is turned on.
Vibration is applied by 5 and 106 to improve the tightness of the iron core. The operation time of the vibration imparting devices 105 and 106 is managed by a timer.

After the vibrations of the vibration applying devices 105 and 106 are stopped, the ironing rollers 69 and 70 are retracted, and the air cylinder 51 is operated to push the joint pressing plate 52 as shown in FIG. It is brought into contact with the joint of the wound core Cu inserted this time.

After the joining portion of the wound core inserted into the coil is rejoined as described above, the air cylinder 50 is operated to bring the roller 61 into contact with the yoke portion y of the wound core Cu. The probe 60a of the vibration sensor 60 is brought into contact with the part y. Next, the servo motor 57 is rotated to
0 is moved in a direction perpendicular to the direction of the winding axis of the coil, and the probe 60a is slid on the outer peripheral surface of the yoke part y.
When the joining is performed well, when the probe 60a moves in a specific direction (for example, when the yoke is joined as shown in FIG. 5, the second yoke half y2 is used). When the probe 60a moves from the side to the first yoke half y1 side), the probe falls and vibrates at the step on the outer periphery of the joint. By detecting the vibration of the probe, the joining of the yoke of the wound core inserted this time is confirmed. According to experiments, it was confirmed that by using a wire having elasticity such as a piano wire as a probe, a step (unevenness) having a minute height of about 0.3 mm can be detected with high sensitivity.

If joining cannot be confirmed by the vibration sensor 60, the apparatus is stopped and an alarm is issued to allow the operator to judge. If the joining is confirmed, the vibration sensor is retracted and the iron core clamp base 10 is raised to prepare for the insertion of the next wound iron core.

When the insertion of the final core to be inserted by the machine is completed and the joining is confirmed, the welding torch 54 is moved to the core side at the position where the joining is confirmed, and the Adhere to the joint. Air cylinder 5
5 is operated to bring the welding ground 56 into contact with the wound core. In this state, electricity is supplied to the welding torch 54, and the final lap at the joint is spot-welded and fixed.

After the welding is completed, the coil gantry 3 is pulled out along the setting rail 2 and the coil into which the iron core is inserted is carried out.

In order to automatically perform the above-described series of operations, an operation of opening the joint portion of one yoke portion y of the wound core Cu and a pair of control bars 46 and 47 are used to connect a pair of coils W , W '
The control bar is moved to the side of the winding core Cu through the window portion and the tips of the pair of control bars are connected to the first yoke half y1 and the second yoke half y1 of the winding core.
And the operation of moving the wound core together with the joint expanding device 30 and the control bars 46 and 47 in the direction of the winding axis of the coil to thereby make the first joint of the wound core y2. The operation of inserting at least the portions having the inclined surfaces of the iron half and the second yoke half into the windows of the pair of coils W and W ′, and inserting the pair of insertion auxiliary bars 96 and 97 toward the winding core. The tip of the pair of insertion assist bars is moved to the first yoke half y1.
And the operation of contacting the second yoke half y2 with both side surfaces on the rear end side of the second yoke half y2, and the clamp and restraint by the clamp 15 after the other yoke of the wound core is supported by the yoke support 102. Of the wound iron core by the joint and the joint expanding device 30
And a pair of control bars 46, 47, insertion assist bars 96, 97, and a yoke support until the pair of legs of the wound core are inserted into the windows of the pair of coils. 10
2 along with the winding core along the winding axis of the coil, and after inserting a pair of legs of the winding core into the windows of the pair of coils, remove the insertion assist bars 96 and 97 from the winding core. Operation, removing one of the control bars 46 from the tip of the first yoke half after inserting the pair of legs of the wound core into the windows of the pair of coils, and second half of the yoke Operation of removing the other control bar 47 from the tip of the core, and removing the one control bar from the tip of the first half of the first yoke of the wound core.
To the action position, and after removing the other control bar 47 from the tip of the second half of the yoke of the wound core, with the joining auxiliary plate interposed between the joints, The operation of pressing the rear ends of the first and second yoke halves toward the respective front ends, and pressing the joint from the outside after removing the joining auxiliary plate from the joint of the wound core. The joint expanding device, the control bar moving mechanism, the insertion assisting bar moving mechanism, the expanding device moving mechanism, the joining auxiliary plate moving mechanism, the yoke half-part pressing mechanism, and the joint pressing mechanism are operated so as to perform the operation. A control device for controlling is provided.

This control device can be easily realized by using a sensor such as a limit switch for confirming the completion of the operation of each unit and a microcomputer for giving an operation command to each unit in a predetermined order according to the output of the sensor. Can be realized.

As described above, according to the present invention, the operation of inserting the wound core can be automated, so that the entire operation of inserting the core into the window of the coil can be automated. Only the above method can be used. For example, in FIG. 7, even if only the winding core C2 occupying the main part of the transformer core Co is inserted by the above-described method, the efficiency of the transformer assembling operation can be greatly improved. Cores C1 and C3 with small thickness
Can be relatively easily inserted even by manual operation.

In the above embodiment, all the steps from the insertion of the wound core to the rejoining of the joint are mechanized. However, the steps from opening the joint of the wound core to inserting it into the coil are mechanized, and the joining is performed. The step of rejoining the parts may be performed manually.

In the above embodiment, the linear drive mechanism is constituted by the motor and the ball screw. However, the linear drive mechanism is constituted by the motor and another rotary / linear motion conversion mechanism such as a rack and pinion mechanism. May be.

In the above embodiment, an air cylinder is used as a cylinder, but a hydraulic cylinder may be used.

In the above embodiment, an electromagnet is used as the yoke support 102. However, this yoke support is constituted by a clamp which clamps the other yoke y 'of the wound iron core Cu in the width direction. You can also.

As in the above embodiment, the insertion assist bar 9
6 and 97 and its moving mechanism, and
6, 97 and the control bars 46, 47, the winding core is moved in the direction of the winding axis of the coil together with the control bar and the auxiliary bar in a state where the vicinity of one end of the yoke portion side of the winding core is sandwiched therebetween. When the pair of legs x, x 'of the iron core are inserted into the windows of the pair of coils W, W', respectively, the legs x, x 'of the wound core are more smoothly inserted into the windows of the windings. However, since the insertion auxiliary bars 96 and 97 are provided as auxiliary, they can be omitted. That is,
Without using the insertion assist bars 46, 47, a pair of coils W,
The tips of a pair of control bars 46, 47 penetrating through the window of W 'are brought into contact with the tips of the first yoke half y1 and the second yoke half y2 of the wound core with the joints opened. The first and second yoke halves of the wound iron core are moved together with the control bars 46 and 47 toward the coils W and W '. After inserting the vicinity of the tip of the coil into the window of the pair of coils, the core is further moved together with the control bar in the direction of the winding axis of the coil, so that the pair of legs of the core is moved by one.
You may make it insert in the window part of a pair of coils.

[0080]

As described above, according to the present invention, the control bar of the control bar is provided at the tip of the first yoke half and the tip of the second yoke half of the wound core with the joint open. The control bar is moved along with the core while the other end of the core is supported by the movable yoke support while the other end of the core is held open by contacting the ends. Since the pair of legs of the iron core is inserted into the window of the pair of coils, the wound core can be smoothly inserted into the window of the coil while being guided by the control bar, thereby damaging the coil and the iron core. There is an advantage that the work of inserting the iron core can be performed without the need.

In particular, according to the second or fourth aspect of the present invention, since the re-joining of the joined portions of the wound core can also be performed by a machine, the entire operation of inserting the iron core into the coil is mechanized and the work efficiency is improved. There are advantages that can be improved.

Further, according to the present invention, since the work of inserting the iron core can be mechanized, it is possible to prevent the quality of the product from being varied due to individual differences among workers.

[Brief description of the drawings]

FIG. 1 is a plan view showing a configuration of an apparatus used in an embodiment of the present invention.

FIG. 2 is a front view of FIG.

FIGS. 3A to 3E are explanatory views for explaining different steps of the method of the present invention.

FIGS. 4A to 4F are explanatory diagrams for explaining other different steps of the method of the present invention.

FIG. 5 is an explanatory diagram for explaining an operation of the vibration sensor used in the embodiment of the present invention.

FIG. 6 is a front view showing a configuration example of a transformer to which the present invention is applied.

FIG. 7 is a cross-sectional view showing a cross section of one coil of the transformer of FIG. 6 and legs of an iron core inside the coil.

FIG. 8 is a cross-sectional view showing an example of a joint structure of a yoke portion of an iron core of the transformer of FIG.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Frame 5 Coil holding device 6 Servo motor 7 Ball screw 8 Iron core moving table 9 Cylinder 10 Iron core clamp table 11 Motor 12 Ball screw 14 Cylinder 15 Clamping tool 16 Motor 17 Ball screw 20, 21 First opening roller 22, 23 First opening arm 24, 25 Second opening roller 30 Joint expanding device 33, 34 Restrainer driving mechanism 35 Expansion device moving mechanism 40 Motor 41 Hole screw 44, 45 Linear driving mechanism 46, 47 Control bar 51 Cylinder 52 Joint holding plate 65 , 66 Cylinder 69, 70 Ironing roller 71, 72 Air motor 80 Motor 81 Ball screw 83 Cylinder 84 Joining auxiliary plate 90 Motor 91 Ball screw 94, 95 Linear drive mechanism 96, 97 Insertion auxiliary bar 100 Motor 102 Yoke support Cu winding iron y One yoke part y1 First yoke half part y2 Second yoke half part J Joint part J1 Stepwise inclined surface facing outward J2 Stepwise inclined surface facing inside W, W 'coil

Claims (4)

(57) [Claims] 1. One of the yoke parts is divided into a first yoke half and a second yoke half, and the first yoke half and the second yoke half are separated from each other. A method of inserting a rectangular core wound into a window portion of a coil by joining a stepped inclined surface having an outwardly directed step and an inwardly directed stepped inclined surface to form a joint, comprising: A step of arranging the coils side by side with the respective winding axes parallel to each other, and displacing the pair of legs of the wound core in the vicinity of one end on the side of the yoke to displace outward. Opening the joining portion to separate the first yoke half and the second yoke half; and joining the tips of the pair of control bars penetrating through the windows of the pair of coils. Abutting the ends of the first yoke half and the second yoke half of the open wound core to hold the joint open; Moving the wound core together with the control bar to the coil side and inserting the vicinity of the tip of the first yoke half and the second yoke half of the wound core into the windows of the pair of coils; Moving the wound core together with the control bar in the direction of the winding axis of the coil, and inserting a pair of legs of the wound core into windows of the pair of coils; Removing the control bar from the tip of the iron half and the tip of the second yoke half. 2. In the step of removing the control bar, first, the control bar is removed from a first yoke half of the wound core, and a joining auxiliary plate is applied to an inclined surface of a tip end of the first yoke half. After that, the control bar is removed from the second yoke half, and the slope of the tip of the second yoke half is changed to the slope of the first yoke half via the joining auxiliary plate. Then, the vicinity of the rear ends of the first yoke half and the second yoke half of the wound core is pressed toward the respective tip end sides, and the inclined surface of the first yoke half and A step of adjusting the positions of the two inclined surfaces of the second yoke half while sliding the inclined surfaces of the second yoke half along the auxiliary joining plate; 2. The method according to claim 1, further comprising the step of: overlapping the inclined surface of the portion with the inclined surface of the tip of the first yoke half to close the joint. 3. One of the yoke portions is divided into a first yoke half portion and a second yoke half portion, and the first yoke half portion and the second yoke half portion are separated from each other. A pair of legs of a rectangular wound iron core, each of which is joined with a step-like inclined surface facing outward and a step-like inclined surface facing inward to form a joint, is inserted into a window of a pair of coils. An iron core insertion device for a transformer to be inserted, a coil holding device for positioning and holding the pair of coils in a state where their winding axes are parallel to each other, and a winding of a pair of coils held by the coil holding device. The one yoke of the pair of legs of the wound core is provided so as to be movable between an operating position and a retracted position on one side in a direction along the rotation axis, and is in the operating position. A pair of restraints for restraining the vicinity of the end on the part side, and the joint of the one yoke is opened to A joint expansion device including a restraint driving mechanism for displacing the pair of restraints so as to separate the distal end of the first yoke half and the distal end of the second yoke half; An expanding device moving mechanism for moving the joint expanding device to the operating position and the retracted position and moving the expanding device in the winding axis direction of the coil; and a pair of coils held by the coil holding device. A pair of control bars arranged so as to extend in parallel with the winding axis, and a control bar support device for supporting the pair of control bars on the other side in the direction along the winding axis of the pair of coils. A control bar moving mechanism for reciprocating the pair of control bars in a direction along a winding axis of the pair of coils; and winding the pair of coils while supporting the other yoke of the wound core. A yoke support provided so as to be movable in the axial direction; Opening the joint of one of the yoke portions of the core; moving the pair of control bars through the windows of the pair of coils toward the wound core so that the tips of the pair of control bars are moved to the wound core; An operation of abutting the tip of the first yoke half and the second yoke half from inside, and moving the wound core along with the joining part expanding device and the control bar in the winding axis direction of the coil. Inserting the vicinity of the distal ends of the first yoke half and the second yoke half of the wound core into the windows of the pair of coils;
An operation of releasing the restraint by the restraint device and moving the joint expanding device to the retracted position after supporting the other yoke portion of the wound core by the yoke support member;
Moving the pair of control bars and the yoke support along with the winding core along the winding axis of the coil until the pair of legs are inserted into the windows of the pair of coils; Removing one of the control bars from the tip of the first yoke half after inserting the pair of legs into the window of the pair of coils, and removing the other control bar from the tip of the second yoke half. Characterized by comprising a control device for controlling the joint expanding device, the control bar moving mechanism, and the expanding device moving mechanism so as to perform the operation of removing the control bar of (1). apparatus. 4. A state in which a pair of legs is inserted into a window of the pair of coils, and one of the control bars covers an inclined surface of a tip end of a first yoke half of the wound core. A joining auxiliary plate provided so as to be able to move between an operating position where the control bar moves and a retreat position which does not hinder the movement of the control bar; and a joining auxiliary plate movement for moving the joining auxiliary plate between the operating position and the retreat position. And a rear end side of the first yoke half and a second yoke half of the core wound with the pair of legs inserted into the windows of the pair of coils. Further comprising: a yoke half-part pressing mechanism that presses the joint part of one of the yoke parts of the wound core from outside, and the control device further includes: An operation of moving the joining auxiliary plate to the operating position after detaching from the tip of the first yoke half; After removing the bar from the tip of the second yoke half of the wound core, the first yoke half and the second yoke of the yoke are provided with the joining auxiliary plate interposed between the joints. The bonding is further performed so that an operation of pressing the rear end portion of the half portion toward the respective front end portion and an operation of pressing the bonding portion from the outside after removing the bonding auxiliary plate from the bonding portion of the wound core are performed. The iron insertion device for a transformer according to claim 3, wherein the auxiliary plate moving mechanism, the yoke half pressing mechanism, and the joint pressing mechanism are controlled.