JP3098570B2 - Amorphous iron core manufacturing method and apparatus - 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 and an apparatus for manufacturing an iron core for a transformer, and more particularly to an amorphous block material in which a plurality of ultra-thin amorphous materials are arranged and provided in a wrap portion in order and wound in layers. The present invention relates to a method and an apparatus for manufacturing an iron core.

[0002]

2. Description of the Related Art Since an amorphous material is extremely thin, having a thickness of about 0.05 mm inside and outside, and has a high hardness, the work of winding a large number of such layers into a transformer core to form a core for a transformer has conventionally been performed.
The productivity is low and a lot of trouble is required for stabilizing the quality. For example, as shown in FIG.
Is cut with a cutter 24 and developed to form a trapezoidal material 25,
After the amorphous block material 10 formed by aligning a plurality of pieces of the amorphous material 1 is again formed into the round material 27,
This is for manufacturing the rectangular core 28. In another conventional technique, as shown in FIG. 13, a plurality of amorphous materials 1 are cut into an amorphous block material 10. After the central portion is pressed and fixed by the upper presser 22, the pressure roller 29 is pressed and formed on the winding die 6 while rolling along the outer periphery, and a tape 30 is applied to the wrapped joint as shown in FIG. The work of attaching and fixing using the pressing pieces 31 is repeated to form the iron core.

[0003]

The prior art shown in FIG. 12 employs a system in which a long round material 23 is rewound and formed into a round material 27 again. An amorphous iron core to be formed and formed, and the wrapped joint part is about 1.5 times as thick as the other parts and the iron core shape after forming becomes almost elliptical, so it is round wound. It is difficult to form, and therefore, generally, a step of forming into a rectangular shape after the round winding is provided, so that the working efficiency is reduced.
Further, after performing the annealing work in a rectangular shape, if the mechanization for reassembly of the coil and the iron core is considered, the occurrence of the misalignment of the lap joint becomes an unavoidable problem. Therefore, an efficient winding means is required without causing the problem. FIG. 6A is an overall view of a rectangular molded iron core, and FIG. 6B is an enlarged detailed view of a wrap portion C. In the prior art shown in FIG. 13, a plurality of pieces of the amorphous material 1 are cut into a block material 10 so as to prevent a displacement of a lap joint, and the blocks are stacked one by one along the outer periphery of the rectangular winding form 6. And form 6
There is a problem in that the winding takes a long time because the winding is performed while pressing the pressure roller 29, and as shown in FIG. Since the portion pressed by the roller 29 forms the concave portion 32, the circumferential length is extended. Further, since the next block material 10 is sequentially laminated and wound on the upper layer of the concave portion 32, there is a problem that the space factor of the iron core cannot be increased. In view of the above problems, an object of the present invention is to provide a method and an apparatus for manufacturing an amorphous core suitable for securing quality, particularly a high space factor, and reducing costs.

[0004]

[Means for Solving the Problems]Achieve the above objectives
,The present invention relates to at least one long amorphous material.
Amorphous blockLumberFormProcess
When,The amorphousBased on one longitudinal end of the block
And then alternately position the left and rightSaid ammo
RufusStack the block material above a substantially rectangular formProcess
And the plurality of setsamorphousBlock material is roughly rectangular
Fix to the formerProcessWhen,SaidAbove a substantially rectangular winding form
The plural sets ofamorphousBlock material in inverted U shape
Droop,PreviousThe plurality of sets of the inverted U-shapedAmole
FassBlock materialBringing both shoulders into close contact with each other;
The morphous block material is squeezed with a few adjacent
Adhesively fixed by pressing force perpendicular to at least three planes
Process and, The plurality of setsamorphousBoth blocks
The free side ends are sequentially laminated and molded and fixed in a loop.ProcessAnd
Have.Also, At least one long amorphousElementary
Align the ingredientsMeans for forming amorphous block material
And one end in the longitudinal direction of the amorphous block material.
And a plurality of sets of the above
Rufus block material is placed above the approximately rectangular winding formMeans of stacking
When,The plurality of sets of amorphousSubstantially rectangular block material
For windingMeans for fixing and suspending the substantially rectangular winding form upward
The above-mentioned plural sets of amorphous block materials into an inverted U-shape.
The plurality of sets of amols suspended in the inverted U-shape.
Means for bringing both shoulders of the fass block material into close contact with each other;
The morphous block material is squeezed with a few adjacent
Adhesively fixed by pressing force perpendicular to at least three planes
And a plurality of sets of amorphousBoth blocks
~ sideFree ends are sequentially laminated to form a loopMoldingMeans to fix
By havingAchieved.

[0005]

[Function] As a sheet material for an iron core, block materials are stacked in order from a short block material having a uniform length.
Positioning is easy to check, and after placing the former under the approximate center of the laminated block material in the longitudinal direction, tightening the flat part, and lifting the former, both ends of the block material are under their own weight. Hanging in the inverted U-shape makes it easier to attach the inverted U-shaped both shoulder presser and the side tightening plate, and the cutting dimension of the block material varies because it is based on one end in the longitudinal direction of the block material. Does not cause a displacement of the lap portion, and the tightening adjustment can be performed so as to have an appropriate space factor.

[0006]

1 to 7, an embodiment of the present invention is shown in FIGS. FIG. 1 shows that a plurality of cut pieces of long amorphous material 1 are cut into one block (in this embodiment, one block is 20 pieces of the same cut size). FIG. 2 is a perspective view of the stacking device, and FIG. Positioning pieces 4a, 4a
, 4b, 4b are positioned using positioning pins 3, 3, on the platforms 2, 2, which are arranged on the left and right with the winding form 6 at the center. The positioning pieces 4a, 4a have a plurality of abutting portions formed in a step-like shape, and the block material 10 is abutted one block at a time alternately on the left and right, and sequentially overlaps in an upward direction. For example, in FIG. 2, when the positioning pieces 4a, 4a are stacked up to the third level, the process moves to the abutting portion of the upper positioning pieces 4b, 4b. At this time, since it is necessary to align the block material 10 also in the width direction, in order to position the block material 10 while pressing it against the pressing plate 5, as shown in FIG. easy.

FIG. 6 shows a front view (a) of an iron core formed according to this embodiment and an enlarged detailed view (b) of a wrap portion C.
When the wrap width reaches a predetermined limit range L as shown in FIG. 4B by stacking one block at a time, the positioning pieces 4b of the next stage are overlapped with each other, as will be described in detail below. The block is configured to return to the initial wrap position by continuing the stacking by alternately abutting the left and right ends on the block 4b one block at a time. The limit range L is
It is a dimension that regulates the limit to which the coil can be mounted after the core is formed, and is set in advance as a predetermined value determined by the specification of the core.

In this way, after the block material 10 corresponding to one iron core is stacked on the former 6 while being held in a substantially straight line, as shown in FIG. It is placed on a stack 10, and the former 6 and the upper clamping plate 7, which are set in the center of the stacking platforms 2 and 2, are firmly fastened with the tightening bolts 8. At this time, the fastening is performed with both ends in the longitudinal direction of the block material 10 being free ends. A lifting suspension bolt 9 is attached to the upper fastening plate 7. As described above, since the former 6 is set in advance between the stackers 2, 2, it is suitable for preventing slack of the block members 10 when stacking them and performing accurate positioning. In the present embodiment, the winding form 6 is substantially rectangular, but is not limited to this, and may be circular or oval.

As shown in FIG. 6B, the first layer 10a is wrapped to the left of the center line 33 with a margin y from the p-line as a starting point, and the second layer 10b is q to the right of the center line 33. It is wrapped with the line y as the starting point. Followed by the third
The layer 10c is wrapped to the left of the center line 33 with y + x starting from the p-line, and the fourth layer 10d is
Is wrapped on the right side of y + x with the q-line as the starting point. Hereinafter, the lap margin increases by x each time starting from the p-line and the q-line alternately on the left and right. Thus, when the lap width reaches the predetermined limit range L, the left and right laps return to the first lap margin y.

In FIG. 2, when the abutting end of the block material 10 is the A end on the left side and the B end on the right side, the abutting end 10aA of the first layer and the abutting end of the third layer are the A end. Since the difference from 10 cA is 2πt (t is the thickness of one block), the piece 4 having a step of 2πt shown in FIG.
Although the shape of c should be good, the wrap margin on the B end side is sequentially increased by x as shown in FIG.
Layer abutment end 10aB and third layer abutment end 10cB
Is in contact with the positioning piece 4a at the B end, which is x + 2πt
Must. Therefore, the positioning piece 4a has a left-right symmetrical shape so that the end A contacts the butting end 10bA of the second layer and the butting end 10dA of the fourth layer. When the lap width limit range L is reached, the lap margin is returned to y.
Is a positioning piece abutting on the side of the abutting end 10A. The same applies to the positioning piece 4b. As a result, even if the cut dimensions of the block material 10 vary, the wrap portion is centrally positioned on the basis of the outside, so the variation occurs at the starting point positions p and q on the center side of the iron core.
Therefore, the predetermined limit L of the wrap width can be always kept constant. The positioning pieces 4a and 4b also serve to prevent the ends from sagging. Instead of the steps of the positioning pieces 4a and 4b, as shown in FIG. 7B, a positioning piece 4d having a graduation line 26 formed on a slope is used. May be used.

In order to manufacture iron cores of different sizes by the stacking apparatus of the above embodiment, it is possible to cope with the problem by adding positioning pieces 4a and 4b or changing the position of the positioning pins 3. And the limit range L of the lap width can be dealt with by changing the positioning pieces 4a and 4b.

In FIG. 1, one block material 10 is stacked on one side of an upper portion of a substantially rectangular winding form 6 and an upper fastening plate 7.
After tightening firmly, the upper tightening plate 7 as shown in FIG.
Block material 10 for lifting through the suspension bolts 9
Does not occur. In this embodiment, the block material 1
Although 0 is fastened to one side of the former 6, the fastening position is not limited to this portion, and may be a corner portion if the shape of the fastening plate is changed. The non-slip piece 11 is used to hold the upper clamping plate 7 at a right angle with the block material 10 when the upper clamping plate 7 is fixed.
The slip stopper 11 naturally comes off when lifted. After being tightened by the upper tightening plate 7, the stacking base 2 is
A mechanism is provided for sliding in the direction away from the block material, and the block 2 is slid after the block material 10 is fastened, so that the block material 10 hangs down along the former 6 and is lifted using the suspension bolts 9. Therefore, the work with the crane can be abolished. At this time, since both ends of the block material 10 are free ends, the block material 10 hangs down by its own weight along the winding form 6, and the amorphous materials 1 constituting the block material 10 can be closely overlapped with no gap therebetween.

In the suspended state, as shown in FIG. 3, a shoulder retainer 12 is attached, and after strongly pressing the inverted U-shaped shoulder portion, a side tightening plate 13 is attached to the three planes of the winding form 6. The block material 10 is firmly fastened. The rotating shaft 14 is mounted on the side mounting plate 13 in advance.

Next, FIG. 4 shows a state where the suspended block material 10 is placed on the reversing table 15 and rotated by 180 °. The block material 10 located on the upper portion is raised in the direction of arrow D by inversion, the wrap portion 16 is combined, fixed with tape, and the lower fastening plate 17 is further fastened.
The term "means for closely fixing a plurality of sets of block members to at least three adjacent planes of a substantially rectangular winding form by pressing force in a right angle direction" in the claims means, for example, in the above embodiment, It refers to fastening by the attachment plate 7 and the side fastening plate 13. "At least" means 12
Means that it is more effective for close contact fixation. The combination of the wrap portions 16 may be performed automatically using an industrial robot or a manipulator. Then, the lap portion 16 is fastened and fixed by the lower fastening plate 17, and then the upper fastening plate 7 and the lower fastening plate 17 are adjusted so as to satisfy the set space factor. Finalize.

In addition to the 180 ° rotation by the reversing table 15 shown in FIG. 4, the combination of the lap portions 16
It may be performed after the winding form 6 is turned over on the other side and the other two planes are fixed.

Another embodiment of the present invention will be described with reference to FIGS. As shown in FIG.
After being conveyed onto the former 6 and positioned, the upper presser 22 is lowered and pressed against the former 6, the shoulder of the block material 10 is pressed by the shoulder press 18, and then the upper presser 22 is set in a direction perpendicular to the upper presser 22 by the horizontal presser 19. Press. This operation is repeated, and after the stacking of the block materials 10 corresponding to one iron core is completed, the upper fastening plate 7 and the side fastening plate 13 are fastened to form an inverted U-shape. These detailed procedures are shown in the flowchart of FIG.

After the winding form 6 is mounted at the center of the apparatus, the cut plurality of blocks of the amorphous material 1 are positioned. The positioning means performs positioning by NC control (numerical control) based on one end in the longitudinal direction according to the above embodiment. Next, after the block material 10 is pressed against the upper part of the former 6 by the upper presser 22, the shoulder portion is pressed by the shoulder press 18, and then the horizontal portion is pressed by the horizontal presser 19. When the horizontal portion is pressed, the upper presser 22 and the shoulder presser 18 are released to wind the next block material 10. When winding of one iron core is completed,
The upper presser 22 is retracted, and the upper tightening plate 7 is fixed with the tightening bolt 8. Next, the shoulder presser 18 is released while the presser is pressed, and the side presser 19 is released. When the tightening is completed, the U-shaped iron core is taken out, the lap portion is combined using a manipulator or the like, and then the lap portion is fixed with the lower tightening plate 17, and finally the space factor is reduced. After adjustment, the forming of the amorphous iron core is completed.

In this embodiment, the blocks are wound one by one. However, the stacking device shown in FIG. 1 is used to automatically position the block material 10 corresponding to one iron core, and then the stacking unit shown in FIG. May be molded at once.

[0019]

According to the present invention, it is possible to efficiently position and stack blocks made of a plurality of amorphous materials having the same dimensions and then form and fix them all at once, or to form and fix by sequentially positioning each block. Accordingly, it is possible to provide an apparatus and a method for easily manufacturing an amorphous iron core having a high space factor at low cost.

[Brief description of the drawings]

FIG. 1 is a perspective view showing one embodiment of a stacking device according to the present invention.

FIG. 2 is a front view showing a main part of FIG. 1;

FIG. 3 is a perspective view showing a state in which the block material is lifted in the embodiment in FIG. 1;

FIG. 4 is a perspective view showing a state in which the state of FIG. 3 is inverted by 180 °.

FIG. 5 is a flowchart of iron core manufacturing in the embodiment of FIG. 1;

FIG. 6 is a front view of an iron core manufactured according to the embodiment of FIG. 1 and an enlarged detailed view of a wrap portion.

FIG. 7 is an embodiment of a positioning piece according to the present invention.

FIG. 8 is an embodiment view showing a manufacturing process by the automatic iron core winding device according to the present invention.

FIG. 9 is a view showing an embodiment of a stacking base according to the present invention.

FIG. 10 is a manufacturing flowchart of the embodiment in FIG. 8;

FIG. 11 is a front view showing a state in which the forming of the amorphous iron core according to the present invention is completed.

FIG. 12 is a view showing a manufacturing process of a conventional iron core.

FIG. 13 is a diagram showing a processing step using a conventional pressure roller.

FIG. 14 is a perspective view showing a processing end step using a conventional pressure roller.

FIG. 15 is an explanatory view showing deformation of a block material due to processing of a conventional pressure roller.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Amorphous material 2 Stacking stand 3 Positioning pin 4a, 4b, 4c, 4d Positioning piece 5 Pressing plate 6 Winding mold 7 Upper clamping plate 8 Tightening bolt 9 Hanging bolt 10 Block material 11 Slip-stop piece 12 Shoulder holding 13 Side tightening Plate 14 Rotating shaft 15 Reversing table 16 Lapping part 17 Lower clamping plate 18 Shoulder retainer 19 Side retainer 20 Upper retainer cylinder 21 Lateral retainer cylinder 22 Upper retainer 23 Round winding 24 Cutter 25 Trapezoidal material 26 Scale wire 27 Round winding material 28 Rectangular Iron core 29 Pressure roller 30 Tape 31 Pressing piece 32 Recess 33 Center line

Claims (2)

(57) [Claims] (1) At least one long amorphous material is
Forming an amorphous block material drawn aligned, a reference to one longitudinal end of said amorphous block material
And a plurality of sets of the above-mentioned
A step of stacking a substantially rectangular former upward Asuburokku material, the substantially rectangular coil form a plurality of sets of amorphous block material
And fixing the, Cupid of the plurality of sets by lifting the substantially rectangular former upward
The fass block material is suspended in an inverted U shape, and the inverted U shape is formed.
The shoulders of the plurality of sets of amorphous block materials depending on
And a step of adhering the amorphous block material adjacent to each other of the winding form.
At least three planes perpendicular to each other.
A method for manufacturing an amorphous iron core, comprising: a step of attaching and fixing; and a step of sequentially laminating free ends on both sides of the plurality of sets of amorphous blocks and forming and fixing them in a loop shape . The method according to claim 2 wherein at least one elongated amorphous Material
Means for aligning and forming an amorphous block material, with reference to one end in the longitudinal direction of the amorphous block material
And a plurality of sets of the above-mentioned
Means for stacking Asuburokku material into a substantially rectangular former upper, substantially rectangular former a plurality of sets of the amorphous block material
Means for fixing the plurality of sets of
Hang the fass block material in an inverted U-shape,
The shoulders of the plurality of sets of amorphous block materials depending on
Means for adhering the part and the amorphous block
At least three planes perpendicular to each other.
An apparatus for manufacturing an amorphous iron core, comprising: means for attaching and fixing; and means for sequentially laminating free ends on both sides of the plurality of sets of amorphous blocks and forming and fixing them in a loop shape .