JP2594933B2 - Transformer manufacturing method - Google Patents

Description

The present invention relates to a method for manufacturing a transformer by forming an iron core with an amorphous magnetic alloy.

[Prior Art] Recently, amorphous magnetic alloys have attracted attention as low-loss iron core materials, and production of power distribution transformers using amorphous magnetic alloys has been studied.

The core of a distribution transformer using silicon steel sheet is 1
Turn-cut rectangular wound iron cores are often used.
This type of iron core is divided into a plurality of iron core blocks in the stacking direction, and a joint of each iron core block is arranged on one side of the iron core.

When manufacturing a one-turn cut iron core, a circular steel core formed by winding a steel strip is unwound and cut every turn, and the cut steel sheet is sequentially wound by shifting the position of the joint. It is formed to form a rectangular core. After annealing the wound core, each steel sheet constituting the wound iron core is separated, and the steel sheets of each turn are sequentially inserted into the windows of the winding wound in another process to assemble the iron core.

The same method as described above has been considered for forming a wound iron core with an amorphous magnetic alloy, but the amorphous magnetic alloy is in the form of a strip with a very thin thickness of about 25μ. In the case of forming a one-turn cut wound core using an amorphous magnetic alloy, a plurality of thin ribbons that are normally overlapped are simultaneously wound to form a single core block.

[Problems to be Solved by the Invention] The one-turn cut amorphous magnetic alloy wound core obtained by the above method is once separated into each core block, and then each core block is inserted into the window of the winding. However, since amorphous magnetic alloys have insufficient rigidity, misalignment is likely to occur at each turn when inserting each core block into the window of the winding and abutting each other. There was a problem of increasing. In addition, if the positions of the buttings are shifted, the core cannot be restored to its original shape, and the performance of the core deteriorates, and the fact that an amorphous magnetic alloy having excellent magnetic properties is used cannot be proved. There was also a problem.

SUMMARY OF THE INVENTION An object of the present invention is to provide a rectangular core having a plurality of core blocks stacked in the stacking direction and having a joint portion of each core block disposed on one side, and a winding fitted to the core. An object of the present invention is to provide a method of manufacturing a transformer, comprising: simplifying an operation of inserting an iron core into a winding, and assembling the iron core without causing displacement of each butting portion.

[Means for Solving the Problems] In the present invention, a step of forming a plurality of laminated blocks each forming a plurality of core blocks by laminating amorphous magnetic alloy ribbons, and forming each laminated block One thin ribbon
A step of inclining the stacking surfaces at both ends in the longitudinal direction in a stepwise manner by shifting the sheets one by one or a plurality of sheets in the longitudinal direction, and positioning the joining portion on one side by sequentially overlapping a plurality of laminate blocks and joining both ends. Forming a rectangular wound core, and removing one side having the joint in a state where three sides other than the one side having the joint of the rectangular core are covered with an insulating material and constrained. The step of opening at the joint, the step of fitting the winding to the wound core having one side opened, and the step of closing the one side of the wound core to which the winding is fitted to form the joint Do.

[Operation] As described above, if the joint is opened while the other three sides except the one having the joint of the rectangular core are covered with the insulating material and constrained, the core is opened when the joint is opened. When the winding is inserted into the winding, and when the opened side is closed after the winding is inserted, the ribbon forming the winding core is wound in the laminating direction, the width direction, and the winding inserted in the iron core. It can be restrained so as not to be displaced in all directions of the winding axis direction. Therefore, after the core is annealed, it is possible to prevent the positions of the laminated ribbons from shifting from each other until the winding is fitted and the joint is closed, thereby preventing the performance of the core from deteriorating. be able to.

Furthermore, if the method of fitting the windings in a state where one side of the iron core is opened after forming the shape of the rectangular iron core as described above, the combination of the iron core and the windings can be easily performed, Manufacturing efficiency can be improved.

Embodiment An embodiment of the present invention will be described below with reference to the accompanying drawings.

1 to 12 show an embodiment of the present invention in the order of steps. In this embodiment, first, as shown in FIG. 1, an amorphous magnetic alloy ribbon 1 is wound around a winding core 2 having a circular cross section for a predetermined number of turns, and a circular winding body 3 having a predetermined thickness is formed. Form. In this case, one amorphous magnetic alloy ribbon may be wound, or a polymer in which a plurality of amorphous magnetic alloy ribbons are stacked may be wound.

Next, the winding core 2 is removed from the wound body 3 and a clamp 4 is attached to a part of the wound body 3 as shown in FIG. The clamp member 4 includes two clamp plates 5 and 6 for clamping the wound body 3 in the radial direction, and a bolt 7 and a nut 8 which are provided one by one and fasten the clamp plates in a direction to draw the clamp plates toward each other.
Consists of After clamping the wound body 3, a pair of bolts
Wound body 3 together with clamp plates 5 and 6 in the part located between 7, 7
Are cut all at once in the radial direction. In FIG. 2, A indicates a cut surface.

After the wound body 3 is cut, one side of the clamp tool 4 cut in half and separated into two parts is removed, and the wound body 3 is developed as shown in FIG. The inclined laminated body 9 is formed.

Next, the laminated body 9 is divided into a plurality of laminated body blocks 9a, 9b,... Respectively constituting a plurality of core blocks of a wound core, and each laminated body block (one in FIG. 4) as shown in FIG. The positions of the thin strips constituting the stacked body block 9a are shifted one by one or a predetermined number, and the stacked surfaces 9a1 and 9a2 at both ends in the longitudinal direction are inclined stepwise. This operation is performed, for example, by disposing an inclined plate at one end in the longitudinal direction of the laminated block and shifting a thin strip constituting the laminated block so as to abut the inclined plate.

Next, the laminated blocks 9a, 9b,... Are sequentially laminated while being wound in a circular shape, and both ends of each laminated block are butt-joined to form a circular wound core 10 as shown in FIG. An example of a winding device used for forming the wound iron core 10 will be described as a fifth example.
It is shown in the figure. In the winding device shown in FIG. 5, an endless belt 12 is wound around guide rollers Rs1 to Rs7, idle rollers Rm1 to Rm6 for tension adjustment, and a winding core 11, which are supported by a fixed frame (not shown). Idle roller
Rm1 to Rm6 are displaceably supported by a mechanism (not shown) and are urged by a spring to apply an appropriate tension to the belt 12 so as not to loosen the belt 12 during the winding operation. Core 11 is a rotating shaft
It is attached to 11a and is rotationally driven by a drive source (not shown).

In order to form the wound core 10 by this winding device, first, as shown in FIG.
The second laminated block 9a is wound, and the laminated surfaces 9a1 and 9a2 at both ends of the block are butt-joined. Next, the first laminated block already wound around the second laminated block 9b
It is wound between 9a and the belt 12, and both ends of the second laminate block 9b are butt-joined. In the same manner, the laminate blocks 9c, 9d,.
When winding a, 9b,..., the joint j of each block is positioned at substantially the same position (in this example, the upper yoke of the iron core) (see FIG. 6).

After the core 10 shown in FIG. 6 is formed as described above, the core 11 is removed, and a rectangular core 13 is inserted in place of the core 11 as shown in FIG. Then, as shown in FIG.
Press type 14 and press the core
By pressing 10, the wound core is formed into a rectangular shape.
Next, the core 13 is held while the core 15 is restrained by the press type 14.
At the same time, it is carried into an annealing furnace and subjected to magnetic field annealing to obtain a one-turn cut rectangular wound core 15. The rectangular core 15 is composed of a plurality of core blocks 9a 'to 9e' formed respectively by the laminated body blocks 9a to 9e, and the joint of each core block is one side of the iron core (in this embodiment, the upper joint). Iron part). FIG. 9 shows an enlarged view of the joint of the wound iron core 15. In this example, the laminated block 9a is shown.
The joining surface of 9e is a step-like inclined surface having three steps. The number of steps on each inclined surface is arbitrary.

Next, as shown in FIG. 8, the winding core 13 is removed, and the other three sides 15b to 15d excluding one side (upper yoke portion) 15a having the joint j of the rectangular core 15 are insulated with an insulating tape ( For example, it is completely covered with a cotton tape 16 to restrain the three sides 15b to 15d. In this way, if the three sides other than the one side 15a having the joint are covered and constrained by the insulating material, the ribbon forming the wound core is fitted in the laminating direction, the width direction and the iron core. Can be restrained so as not to be displaced in all directions in the winding axis direction of the winding (the longitudinal direction of the leg on which the winding is fitted).

In this way, the other 3 excluding one side 15a having the joint j
After completely covering and restraining the sides with the insulating tape, the side 15a having the joint j is opened right and left at the joint, and
5a is separated into two halves 15a1 and 15a2, and a frame 17 is fitted to both halves as shown in FIG. The frame 17 is formed in a U-shape as shown in FIG. 11 by a strong material such as a steel plate, and the two halves are fitted to the halves 15a1 and 15a2, and the two halves are legs 15b of the iron core. , 15d. In this state, as shown in FIG.
Transformer windings 18 and 19 wound in different processes are fitted to the two sides 15b and 15d serving as leg portions of the iron core. Since one side 15a constituting the yoke portion of the iron core is opened right and left at the joint portion, the windings 18 and 19 can be easily fitted.

In order to facilitate the work of opening one side 15a having the joint j, an inner corner 15r (see FIG. 8) between one side 15a of the wound iron core 15 and two sides 15b and 15d serving as legs is provided. It is preferable to add a radius.

After fitting the windings 18 and 19, the frame 17 is removed, the opened side (upper yoke portion) 15a is closed, and the joint j is formed again.
A frame 20 made of a resin molded product as shown in FIG.
And the upper yoke portion is covered and restrained by the frame 20. The frame 20 shown in FIG. 13 is composed of halves 2A and 20B fitted to the upper yoke of the iron core from both sides in the width direction of the yoke, and each half shown in FIG. The cover includes a side plate portion 20a to cover, an outer peripheral wall portion 20b covering the outer peripheral surface of the iron core, and a cover plate portion 20c engaged in the window portion of the iron core to cover the inner peripheral surface of the iron core.

Since it is better that the corners connecting the three sides 15b to 15d of the rectangular core 15 have some freedom of movement, the covering of the corners should be loosened, or only the corners should be restrained later. You may. Alternatively, only the corners may be fixed with resin.

In the above embodiment, the tape 16 is wound and the frame 20 is attached after a thin metal plate or a self-supporting plate such as a press board is applied to the inner periphery and the outer periphery of the wound core 15, respectively. Is also good.

As in the above embodiment, the outer surface of the iron core is
When the structure is completely covered by 20, the fragile amorphous alloy chipped when the transformer is immersed in the insulating oil can be eliminated, and the generated fragments can float in the insulating oil and reduce the possibility of lowering the dielectric strength. . However, the present invention is not limited to the case where the outer surface of the iron core is completely covered as described above.
In the step shown in the figure, only a part of the iron core may be covered.

In the above description, the cotton tape 16 is used as a means for restraining the other three sides except the one side having the joint of the rectangular iron core 15, but the insulating tape such as a press board or kraft paper is used. The sides 15b to 15d may be covered and restricted.
Also, the frame of the resin molded product is fitted to the three sides 15b to 15d,
The sides may be covered and restricted.

In the above embodiment, the clamp plate constituting the clamp member 4 when the wound body 3 is cut in the process shown in FIG.
Although the cuts 4 and 5 are cut together, the wound body 3 may be cut between the divided portions of the clamp by using a clamp having a two-part structure.

In the above embodiment, the transformer was assembled by inserting a single wound core 15 into the window of the winding.However, if the required core cross-sectional area was large and the weight of the entire core was heavy, the core was replaced. The unit core may be divided into a plurality of unit cores, and each unit core may be manufactured by the same method as described above. Figures 14 to 17
The figure illustrates how to split the iron core in this case.
Fig. 14 and Fig. 15 show that the iron core 15 is
This is an example of dividing into A and 15B. FIG. 16 shows a case where the iron core 15 is divided into two in the width direction and the laminating direction so that a total of four unit wound iron cores 15 are formed.
This shows an example in which the iron core 15 is constituted by A1, 15B1, 15A2 and 15B2. FIG. 17 shows an example in which the iron core 15 is divided into two unit wound iron cores 15A 'and 15B' in the laminating direction.

As described above, when the iron core 15 is divided into a plurality of unit cores, the core can be inserted into the window of the winding by handling a lighter unit core. Mounting work can be facilitated.

In the above embodiment, after forming the wound core shown in FIG. 2 by winding the amorphous magnetic alloy, the laminated core 9 is formed by cutting and unrolling the wound core. Is divided into a plurality of laminate blocks 9a, 9b,.
The laminate block 9a, 9b,... Is formed by cutting a plurality of amorphous magnetic alloy ribbons or a polymer of a plurality of amorphous magnetic alloy ribbons into a predetermined length without winding and laminating them. It may be formed.

[Effects of the Invention] As described above, according to the present invention, the joining portion is opened while the other three sides except the one side having the joining portion of the rectangular core are covered with the insulating material and constrained. Therefore, when opening the joint, when fitting the winding to the iron core, and when closing one side opened after fitting the winding, the ribbon constituting the winding core is laminated in the laminating direction, width direction and The winding can be restrained so as not to shift in all directions of the winding axis direction of the winding fitted to the iron core. Therefore, according to the present invention, after the core is annealed, the positions of the laminated ribbons can be prevented from shifting from each other until the winding is fitted and the joint is closed, and the performance of the core is reduced. There is an advantage that it can be prevented from lowering.

Further, in the present invention, since a method is adopted in which the winding is fitted in a state in which one side is opened after forming the rectangular core, the combination of the core and the winding can be easily performed, and the manufacturing efficiency is improved. Can be done.

[Brief description of the drawings]

1 to 13 show an embodiment of the present invention. FIG. 1 is a front view showing a step of forming a wound body by winding an amorphous magnetic alloy ribbon, and FIG. FIG. 3 is a front view showing a step of clamping and cutting the wound body, FIG. 3 is a front view showing a laminated body formed by developing the wound body, and FIG. 4 is a diagram showing the laminated body of FIG. FIG. 5 is a front view showing a state in which both end faces of one separately formed laminate block are inclined, and FIG.
FIG. 6 is an explanatory view illustrating a process of sequentially winding the laminated body blocks to form a circular wound core, FIG. 6 is a front view of the obtained wound core, and FIG. 7 is a rectangular shape of the wound core of FIG. FIG. 8 is a front view illustrating a step of covering and restraining three sides of a rectangular wound iron core, FIG. 9 is an enlarged view of the vicinity of a joint portion of the iron core in FIG. The figure shows a 1 with a core joint
FIG. 11 is a front view showing a cross section of the winding portion in a state where the winding is fitted by opening the side, FIG. 11 is a perspective view of a frame used in the process of FIG. 10, and FIG. 12 is fitted with the winding FIG. 13 is a front view showing a state in which one side of the iron core that has been opened is closed and a frame is attached to the one side.
FIG. 14 is a perspective view of a frame used in the step of FIG. 12, FIG. 14 is a perspective view of a transformer obtained by another embodiment of the present invention, and FIG.
The figure is a sectional view showing the split structure of the iron core of the transformer of FIG.
FIG. 16 and FIG. 17 are cross-sectional views showing other different examples of the iron core division structure. DESCRIPTION OF SYMBOLS 1 ... Amorphous magnetic alloy ribbon, 2 ... Core, 3 ... Wound body, 4 ... Clamping tool, 9 ... Laminated body, 9a to 9e ... Laminated body block, 10 ... Wound core , 15 …… Rectangular wound iron core, 16…
... Tape that restrains three sides of the rectangular core, 17 ... Frame that restrains both sides of the open joint of the iron core, 18,19 ... Winding, 20 ... One side having the joint of the iron core Frame to cover.

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Kazuhiro Tanaka 2-1-1-11 Tagawa, Yodogawa-ku, Osaka Co., Ltd. Inside Daihen Corporation (72) Inventor Masatake Hirai 2-1-1-11 Tagawa, Yodogawa-ku, Osaka Co., Ltd. Daihennai (72) Inventor Takeshi Uchikura 2-1-1-11 Tagawa, Yodogawa-ku, Osaka-shi Daihen Corporation (72) Inventor Hiroyuki Nojiri 2-1-1, Tagawa, Yodogawa-ku, Osaka-shi Daihennai (56) Reference Document JP-A-61-40017 (JP, A)

Claims (1)

(57) [Claims] 1. A rectangular core comprising a plurality of core blocks stacked in a laminating direction and having a joint portion of each core block arranged on one side, and a winding fitted to the core. A method of manufacturing a transformer comprising: laminating amorphous magnetic alloy ribbons to form a plurality of laminated blocks constituting each of the plurality of iron core blocks; and forming thin layers constituting each of the laminated blocks. A step of shifting the strips one by one or a plurality of pieces in the longitudinal direction to incline the lamination surfaces at both ends in the longitudinal direction in a stepwise manner; Forming a rectangular core wound on one side; and forming the rectangular core with the joining part in a state where three sides other than the one side having the joining part are covered with an insulating material and constrained. Open the side at the joint And a step of fitting a winding to the wound core having the one side opened, and a step of forming a joint by closing the one side of the wound core fitted with the winding. Characteristic method of manufacturing a transformer.