JP4233102B2 - High frequency ultralight water-cooled welding transformer and its output coil - Google Patents

Description

  The present invention relates to a high-frequency ultralight water-cooled welding transformer used for a spot welder of a welding robot and an output coil in the transformer.

  Welding robots frequently used in automobile factory production lines are equipped with spot welders (resistance welding) on the robot arm. The welding transformer of this spot welder is used to improve the mobility and economy of the welding robot. The weight is reduced from the viewpoint, and the core is made smaller by mainly using the high frequency system, and the output coil is made smaller by using the water cooling system. In other words, the cross-sectional area of the core is inversely proportional to the frequency of the high-frequency alternating current, so if the frequency is increased, the size can be reduced, and the output coil has a large current flowing at the moment of welding. This is because the temperature rises to a high temperature due to the resistance, but if the cooling water channel is formed inside the conductor of the output coil and forced cooling is performed, the conductor cross-sectional area can be reduced and the weight can be reduced. The output coil is usually a half-wave rectification type one turn, a full-wave rectification type one turn each and a convenient two turns. Are stacked.

By the way, the invention of the following Patent Document 1 is disclosed in relation to the above-described high-frequency water-cooled welding transformer. In the invention of Patent Document 1, the high-frequency water-cooled welding transformer has a cooling water passage inside the conductor of the output coil, so that the conductor of the output coil becomes thicker and the reactance drop due to leakage magnetic flux increases, and Since the skin effect is generated by the high frequency itself and the harmonics generated by switching and the AC resistance of the output coil is increased, each of the cooling water passages penetrating the inside is developed to solve these problems. A pair of saddle-shaped output coils of one turn are divided into a plurality of thin pairs of saddle-shaped output coil pieces having cooling channels, and are electrically connected in parallel, and the saddle-shaped output coil pieces are electrically connected in series. In addition, the above-mentioned problem is solved by sandwiching with an input coil composed of a plurality of hook-shaped input coil pieces.
JP-A-5-82358

  However, it is extremely difficult to form a cooling water passage uniformly through the conductor of the bent hook-shaped output coil, and if it is to be a plurality of thin bowl-shaped output coil pieces having cooling water passages as well. More difficult. Moreover, in practice, such a configuration makes the structure remarkably complicated and increases the number of parts, making it difficult to manufacture, increasing costs, and making it more difficult to reduce the size and weight. Furthermore, the coupling coefficient between the input coil and the output coil cannot be sufficiently increased, and the reactance drop due to the leakage magnetic flux cannot be sufficiently reduced.

  On the other hand, it is conceivable that the output coil itself is formed of a conductive pipe and is also used as a cooling water channel. However, in such a configuration, the coupling coefficient between the output coil and the input coil becomes very low, Since the required conductor cross-sectional area cannot be secured, it is not suitable as a high-frequency water-cooled welding transformer.

The present invention is intended to solve the above-described problems, and the high-frequency ultra-light water-cooled welding transformer of the present invention has a vertical width and a horizontal length corresponding to the entire outer periphery of the cylindrical input coil mounted on the core. The output terminal is integrally projected from the upper corner of one end of the conductive plate having the required thickness and the lower corner of the other end, respectively, and the center tap is integrally projected from the middle portion of the one end and the other end, and Inclined straight cuts with a certain gap from between the output terminal at one end and the center tap to between the output terminal at the other end and the center tap, each having an output terminal and a center tap A pair of upper and lower output coil pieces are formed, both output coil pieces are bent into a cylindrical shape, and attached to the entire outer peripheral surface of the input coil in a single band shape, and the center taps are joined to each other. Te, an output coil that covers the outer peripheral whole on the outer circumference of the input coils provided, annexed integrally the cooling channel to the outer surface of the output coil, those formed by protruding outside the output coil a flow path port of the cooling water passage is there.

According to the present invention, because of the above configuration, the coupling coefficient between the input coil and the output coil can be sufficiently increased to suppress the leakage magnetic flux as low as possible even with the full-wave rectification type. At the same time, the capacitance distributed between the input coil and the output coil can be increased, and this high capacitance equivalently forms a series circuit with the inductance. In addition, the skin effect of the output coil can be suppressed and the AC resistance generated in the output coil can be sufficiently reduced. Further, the cooling water passage of the output coil is attached to the outer surface of the conductive plate, and the flow passage opening is provided. Since it only needs to protrude outward from the output coil, the overall size and weight of the coil can be increased, and the size and weight of the core can be increased accordingly. , Improvement in performance of the welding transformer and can achieve miniaturization and weight reduction can be adapted in the best condition to a high-frequency inverter. Even if it is a full-wave rectification type, the structure can be simplified, the number of members can be reduced, the processing and assembly of each member can be facilitated, the waste of materials can be saved, and the cooling water channel can be reduced. It can be easily formed with a copper tube, etc., and the cooling water channel can be easily attached and integrated to the outer surface of the conductive plate by a simple joining means such as soldering, and the yield can be improved. Cost can be greatly reduced and good products can be provided at low cost.

  Moreover, because of such a configuration, the output coil can be structured as shown in the section of the best mode for carrying out the invention below, and even if it is of a full-wave rectification type, it is reasonable. In addition, it can be manufactured simply and extremely easily at low cost, and the bolts and nuts of the center tap below can also be used as terminals.

  In addition, since it is the said structure, if necessary, a heat sink can also be easily attached outside a cooling water channel, and a cooling effect can be heightened by doing in this way.

In the above-described high frequency ultralight water-cooled welding transformer, the conductive plate forming the pair of upper and lower output coil pieces is a copper plate, the cooling water channel is formed of a copper tube, and the copper tube is output as a pair of upper and lower outputs. Solder along the outer surface of the coil piece .

Also, the output coil has a vertical width and a horizontal length corresponding to the entire outer periphery of the cylindrical input coil mounted on the core, and has a required thickness from the upper corner of one end and the lower corner of the other end. Each of the output terminals is integrally projected, and the center tap is integrally projected from the middle part of one end and the other end thereof, and both center taps are provided with through holes at appropriate locations other than the base and the base, and The output terminal and the center tap are respectively provided with an incision of an inclined straight line having a certain gap from between the output terminal at one end and the center tap to between the output terminal at the other end and the center tap. forming a pair of upper and lower output coil pieces, both output coil pieces together is bent in a tubular shape so as to be attached to the single band wound shape on the outer peripheral surface the whole area of the input coil, further, the both center tap Together to be mechanically electrically joined by the both bolt and nut perpendicularly both the center tap by bent through in place of the through hole other than the base portion outwardly, the base portion of both the center tap The cooling water passage is inserted into the through hole, and the cooling water passage is integrally attached to the outer surfaces of the pair of upper and lower output coil pieces.

  1 to 9 show a full-wave rectification type high frequency ultralight water-cooled welding transformer according to the present invention.

As shown in the drawing, mounting the input coil 2 to the cut core 1, the output coil 4 of the full-wave rectification formed by bending so as to correspond to the conductive plate 3 in a cylindrical shape on the outer periphery whole of the input coil, the A single band is attached to the entire outer periphery of the input coil 2, the cooling water passage 5 is integrally attached to the outer surface of the conductive plate of the output coil 4, and the flow path ports 6 and 7 of the cooling water passage 5 are connected to the output coil 4. Project outward from

  As shown in FIGS. 2 and 9, the input coil 2 has two cylindrical spiral coils 2a and 2b having the same shape in the axial direction and electrically connected in parallel.

  As shown in FIG. 5, the full-wave rectification type output coil 4 has a vertical width and a horizontal length corresponding to the entire outer periphery of the input coil 2 and is placed on one end of a conductive plate 3 made of a copper plate having a required thickness. The output terminals 8a and 8b are integrally projected from the corner and the lower corner of the other end, respectively, and the center taps 9a and 9b are integrally projected from the middle of the one end and the other end, respectively. Are provided with screw holes 10a and 10b, and both center taps 9a and 9b are respectively provided with a base portion and through holes 11a, 12a, 11b and 12b at appropriate locations other than the base portion, and an output terminal 8a and a center tap 9b at one end thereof. An inclined straight notch 13 having a slight insulating gap is inserted between the output terminal 8b and the center tap 9a between the other end and the output terminal 8b and the center tap 9a. Upper and lower pair of output coil piece 14a, to form a 14b.

Next, as shown in FIGS. 3 and 5 to 8, both output coil pieces 14a and 14b are both bent into a cylindrical shape, and the base portions of both output terminals 8a and 8b are both outwardly cranked and both The center taps 9a and 9b are bent outward at right angles to the outside at right angles , and both output coil pieces 14a and 14b are connected to the entire outer peripheral surface of the input coil 2 as shown in FIGS. The two center taps 9a and 9b are abutted with each other through a heat-resistant insulating sheet 15, and both the center taps 9a and 9b are abutted with each other. center tap 9a, mechanically electrically joined and 9b both also both center tap 9a, through hole 11a of the base of 9b, the 11b is passed through the cooling water passage 5, the cooling water passage 5 of the upper and lower output The coil pieces 14a and 14b are integrally attached to the outer surface of the coil pieces 14a and 14b.

  As shown in FIGS. 3 and 4, a copper pipe is used for the cooling water channel 5, and this is formed into a two-turn spiral shape that fits the outer surfaces of the pair of upper and lower output coil pieces 14 a and 14 b, and an intermediate portion thereof is formed. Inserted into base through holes 11a and 11b drilled in both center taps 9a and 9b of the output coil 4, and as shown in FIGS. 2 and 3, formed on the outer surface of a pair of upper and lower output coil pieces 14a and 14b made of copper plates. Solder 17 along. The copper tube is not limited to a circular cross section, but may be a semicircular shape, a triangular shape, a quadrangular shape, or other polygonal shapes, and may be U-shaped depending on circumstances.

  As shown in FIGS. 1 and 2, the input coil 2 or the output coil 4 with the cooling water channel 5 is provided with a heat-resistant insulating mold 18 made of epoxy resin or the like on the inside and outside thereof.

  As shown in FIG. 5, if the output coil 4 is cut from a rectangular material having a predetermined size including the size of the output terminals 8a and 8b and the center taps 9a and 9b at both ends, Although an unnecessary part will arise in the upper corner of the other end side, this part can be utilized as reinforcing pieces 19a and 19b for both output terminals 8a and 8b. In FIG. 2, reference numeral 20 denotes a heat radiating plate attached to the outside of the cooling water channel 5 as necessary. The heat radiating plate 20 is provided so as to sandwich the cooling water channel 5 with the output coil 4, thereby enhancing the cooling effect. be able to.

  The conductive plate 3 and the cooling water channel 5 of the output coil 4 are not limited to copper members, but may be other conductive members. Further, the joining of both is not limited to soldering, but may be brazing, various weldings, or the like as long as the material matches.

  The high frequency ultralight water-cooled welding transformer of the present invention is not limited to a spot welding machine of a welding robot, and can be widely used as other welding transformers.

It is a perspective view which shows the Example of the high frequency ultralight water-cooling type welding transformer which concerns on this invention. It is a vertical front view of the same Example. It is an assembly perspective view of the input coil of the same Example, and the output coil with a cooling water channel. It is a perspective view of the cooling water channel of the Example. It is an expansion | deployment front view of the output coil of the Example. It is an output coil front view of the same Example. It is an output coil side view of the Example. It is an output coil top view of the Example. It is an electric circuit diagram of the same embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Cut core 2 Input coil 2a, 2b Cylindrical spiral coil 3 Conductive plate 4 Output coil 5 Cooling water channel, flow path port 8a, 8b Output terminal 9a, 9b Center tap 10a, 10b Screw hole 11a, 12a, 11b, 12b Through-hole 13 Cut 14a, 14b Output coil piece 15 Heat-resistant insulating sheet 16 Bolt / nut 17 Soldering 18 Heat-resistant insulating mold 19a, 19b Reinforcing piece 20 Heat sink

Claims (3)

The output terminal is integrated from the upper corner of one end and the lower corner of the other end of the conductive plate with the required width and length corresponding to the entire outer circumference of the cylindrical input coil attached to the core. The center tap is protruded integrally from the middle part between one end and the other end, and between the output terminal and the center tap at one end to between the output terminal and the center tap at the other end. And a pair of upper and lower output coil pieces each having an output terminal and a center tap are formed, and both the output coil pieces are bent into a cylindrical shape to form the input coil. A single strip is attached to the entire outer peripheral surface, and both center taps are joined to each other, and an output coil that covers the entire outer peripheral surface is provided on the outer periphery of the input coil, and a cooling water channel is formed on the outer surface of the output coil. Integrally annexed, high-frequency ultra-light water cooled welding transformer, characterized in that the flow path opening of the cooling channel is protruded out of the output coil. The conductive plate forming the pair of upper and lower output coil pieces is a copper plate, the cooling water channel is formed of a copper pipe, and the copper pipe is soldered along the outer surface of the pair of upper and lower output coil pieces. wherein the high-frequency ultra-light water cooled welding transformer. The output terminal is integrated from the upper corner of one end and the lower corner of the other end of the conductive plate with the required width and length corresponding to the entire outer circumference of the cylindrical input coil attached to the core. The center tap is integrally projected from the middle part between the one end and the other end, and both the center taps are formed with through holes at appropriate locations other than the base part, and an output terminal at one end of the center tap. A pair of upper and lower output coil pieces each provided with the above-mentioned output terminal and center tap by making a slanted straight cut with a certain gap from between the center tap and between the output terminal at the other end and the center tap. is formed and both the output coil pieces together is bent in a tubular shape so as to be attached to the single band wound shape on the outer peripheral surface the whole area of the input coil, further, perpendicularly folded to both outside the two center tap Together to be mechanically electrically joined by being allowed to bolt and nut both center tap through in place of the through hole other than the base, it is passed through the cooling water passage to the through hole of the base of the both center tap An output coil of a high-frequency ultralight water-cooling welding transformer, wherein the cooling water passage is integrally attached to the outer surfaces of the pair of upper and lower output coil pieces in series.

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