JP5869305B2 - Welding transformer and manufacturing method thereof - Google Patents

Description

  The present invention relates to a welding transformer having an improved structure of a laminated iron core and a manufacturing method thereof.

  A resistance welding machine such as a spot welding machine includes a welding transformer so that a large current can be instantaneously supplied. The welding transformer has a laminated iron core that forms a magnetic circuit, and the laminated iron core couples the primary circuit on the input side and the secondary circuit on the output side with mutual inductance.

  The welding transformer is roughly classified into an inner iron type and an outer iron type depending on the arrangement relationship between the iron core and the coil, and the outer iron type is generally used. The inner iron type arranges a coil around the iron core, and the outer iron type arranges the iron core around the coil.

  As with a general transformer, the welding transformer employs a laminated iron core in order to reduce eddy current loss. For example, the laminated iron core is formed by insulatingly covering a thin flat steel plate (electromagnetic steel plate) cut into a rectangular shape and laminating a plurality in the thickness direction. For example, Patent Document 1 discloses a laminated iron core in which a plurality of punched non-oriented silicon steel sheets having a predetermined shape are laminated and fixed by rivets.

  In addition, as an iron core that is easy to assemble, there are a wound core wound by insulating a strip-shaped rolled steel sheet, or a cut core type wound core that is annealed and impregnated with an adhesive and then cut into two pieces. is there.

JP-A-11-186062

  However, the conventional laminated iron core uses a plurality of flat steel plates having different shapes and plate widths. Therefore, it is necessary to change the setting of the press machine for each shape and width and punch a flat steel plate, which increases the number of cutting steps for the flat steel plate. Moreover, since the conventional laminated iron core arranges the lamination direction of all the flat steel plates in one direction, the number of flat steel plates used (the number of laminated steel plates) increases. For this reason, the assembly time of a laminated iron core becomes long, and the manufacturing cost of a welding transformer increases.

  On the other hand, since the wound core and the cut core type iron core are rolled and rolled by a winding machine, the number of cutting steps of the electromagnetic steel sheet can be reduced, and the assembly time can be shortened. On the other hand, a winding machine, a heat treatment tank, an adhesive impregnation furnace, a winding core cutting machine, and the like must be provided, and expensive equipment investment and a large site area are required for manufacturing the iron core.

  The present invention was devised in view of the above circumstances, and even if a laminated iron core is adopted, the number of cutting steps and the number of laminated steel sheets can be reduced, and the assembly work time of the laminated iron core can be shortened. It is an object of the present invention to provide a welding transformer that can easily form a coil and reduce manufacturing costs, and a manufacturing method thereof.

  A welding transformer for achieving the above object has a plurality of intermediate laminates and a plurality of sandwich laminates. The intermediate laminate is formed by laminating a plurality of rectangular flat steel plates having the same width and length in the thickness direction of the flat steel plates. In the sandwich laminate, rectangular flat steel plates having the same width as the intermediate laminate are laminated in the thickness direction of the flat steel plates.

  The width direction of the intermediate laminate and the sandwich laminate is aligned in the same direction. The plurality of intermediate laminates are arranged at intervals, and the lengths of these intermediate laminates are aligned. A coil is wound around the intermediate laminate in a ring shape. The plurality of sandwiched laminates sandwich the arranged intermediate laminates from both sides in the length direction of the intermediate laminate.

  The pair of assembly flanges sandwich the intermediate laminate and the sandwich laminate from both sides in the width direction.

  In the present invention, the width of the rectangular flat steel plate means the short side of the flat steel plate, and the length of the rectangular flat steel plate means the long side of the flat steel plate. Further, the “width direction” means the short side direction of a laminate composed of a plurality of flat steel plates, and the “length direction” means the long side direction of a laminate composed of a plurality of flat steel plates.

  According to the welding transformer according to the present invention, the width of the flat steel plate that forms the intermediate laminate and the width of the flat steel plate that forms the sandwich laminate are aligned to the same width. Therefore, it is not necessary to change the setting of the punching width of the press machine, and the number of cutting steps for the flat steel plate can be reduced.

  Further, the width direction of the intermediate laminate and the sandwich laminate is aligned in the same direction. On the other hand, the length direction of the intermediate laminate and the sandwich laminate intersects, and a coil accommodation space for accommodating the coil is defined by a combination of the planes of the intermediate laminate and the sandwich laminate.

  Therefore, the lamination direction of the intermediate laminate and the lamination direction of the sandwich laminate intersect, and all flat steel sheets do not face one direction as in the conventional structure, so the number of flat steel sheets used (number of laminated sheets) is reduced. can do. Further, since the coil can be inserted into the intermediate laminate without the sandwich laminate, assembly of the welding transformer is facilitated.

  As a result, even if a laminated iron core is adopted, the number of cutting steps and the number of laminated steel sheets can be reduced, the assembly time of the laminated iron core can be shortened, and the manufacturing cost of the welding transformer can be reduced.

It is the front view and side view which show the laminated iron core of the welding transformer of Embodiment 1. It is a top view which shows the upper open state of the welding transformer of Embodiment 1. It is a side view which shows the welding transformer of Embodiment 1. FIG. It is the front view and side view which show the laminated iron core of the welding transformer of Embodiment 2. It is a top view which shows the upper open state of the welding transformer of Embodiment 2. 10 is a flowchart of a method for manufacturing a welding transformer in the third embodiment. It is the front view and side view which show the laminated iron core of the welding transformer of a comparative example.

  Hereinafter, with reference to the drawings, the embodiment of the welding transformer according to the present invention will be referred to as [Embodiment 1] and [Embodiment 2], and the embodiment of the welding transformer manufacturing method according to the present invention will be referred to as [Embodiment 3]. explain.

[Embodiment 1]
The welding transformer according to the first embodiment will be described with reference to FIGS. 1 to 3. FIG. 1 is a front view and a side view showing a laminated iron core of a welding transformer according to a first embodiment. FIG. 2 is a plan view illustrating an upper open state of the welding transformer according to the first embodiment. FIG. 3 is a side view showing the welding transformer of the first embodiment.

  The welding transformer 100 according to the present embodiment can reduce the number of cutting steps and the number of laminated steel sheets while adopting the laminated core 2 so that the assembly work time of the laminated core 2 can be shortened. Become.

  The welding transformer 100 according to the present invention is characterized by an iron core structure. As shown in FIG. 2, the welding transformer 100 of the first embodiment has a coil 3 and a laminated iron core 2, and has an outer iron shape in which the laminated iron core 2 is arranged around the coil 3.

  The laminated core 2 forms a magnetic circuit and couples the primary circuit on the input side and the secondary circuit on the output side with mutual inductance. The laminated core 2 is configured by combining a plurality of laminated bodies 20. Each laminate 20 is, for example, an aggregate in which a plurality of rectangular thin flat steel plates 12 having a width and a length are laminated in the thickness direction.

  Here, in the present invention, the “width” of the rectangular flat steel plate 12 means the short side of the flat steel plate 12, and the “length” of the rectangular flat steel plate 12 means the long side of the flat steel plate 12. Means. Further, “width direction” means the short side direction of the laminate 20 composed of a plurality of flat steel plates 12, and “length direction” means the long side direction of the laminate 20 composed of a plurality of flat steel plates 12. . In the case of the square flat steel plate 12, there is no substantial distinction between “width” and “length”.

  As the flat steel plate 12, it is preferable to use an electromagnetic steel plate with little iron loss and high saturation magnetic flux density and magnetic permeability. Examples of the electromagnetic steel plate include a silicon steel plate, and a directional silicon steel plate that is easily magnetized in a specific direction may be used. In addition, an amorphous magnetic material may be used particularly for the purpose of reducing loss.

  The thickness of the flat steel plate 12 is, for example, about 0.5 mm, considering the ease of punching with a press machine, but is not limited to this thickness.

  For example, each flat steel plate 12 is immersed in an insulating solvent such as a natural resin compound such as varnish or a synthetic resin to insulate the surface of the steel plate, and then laminated in the thickness direction to form the laminate 20.

  The laminate 20 includes a plurality of intermediate laminates 21 and a plurality of sandwich laminates 22. The laminate 20 of the present embodiment includes three sets of intermediate laminates 21a, 21b, and 21c and a pair of sandwich laminates 22a and 22b.

  The intermediate laminate 21 is formed by laminating a plurality of rectangular flat steel plates 12 having the same width and length in the thickness direction. The sandwich laminate 22 is formed by laminating rectangular flat steel plates 12 having the same width as the intermediate laminate 21 in the thickness direction. The number of flat steel plates 12 laminated in the intermediate laminate 21 and the sandwich laminate 22 may be the same or different. This is because the thickness of the flat steel plate 12 that forms the intermediate laminate 21 and the thickness of the flat steel plate 12 that forms the sandwich laminate 22 may vary depending on the density of the magnetic flux that passes through the intermediate laminate 21 and the sandwich laminate 22. . By aligning the intermediate laminate 21 and the sandwich laminate 22 with the same width, it is not necessary to change the punching width of the press machine between the intermediate laminate 21 and the sandwich laminate 22, so that the number of cutting steps of the flat steel plate 12 is reduced. Reduced.

  When the laminated core 2 is assembled, the width direction of the intermediate laminate 21 and the sandwich laminate 22 is aligned in the same direction. In the present embodiment, the width direction of the intermediate laminate 21 and the sandwich laminate 22 is aligned with the front-rear direction FR of the laminate core 2 as shown in FIG.

  The length direction of the plurality of intermediate laminated bodies 21 a, 21 b, 21 c is aligned with the height direction HL of the laminated core 2. And these intermediate | middle laminated bodies 21a, 21b, and 21c are arrange | positioned at intervals for mounting | wearing with the coil 3 on one clamping laminated body 22a. The arrangement direction of these intermediate laminates 21a, 21b, and 21c is the length direction of the sandwich laminate 22a and coincides with the left-right direction LR of the laminate core 2.

  That is, in the welding transformer 100 of the first embodiment, as shown in FIG. 1A, three sets of intermediate laminates 21a, 21b, and 21c are erected vertically at both ends and the middle in the length direction of the sandwich laminate 22a. I am letting. By assembling in this way, a space 30 having an open top is defined between the intermediate laminates 21a and 21b and between the intermediate laminates 21b and 21c. This space 30 is a coil housing space for mounting the coil 3 formed in advance on the laminated iron core 2.

  In the present embodiment, among the three sets of intermediate laminates 21a, 21b, and 21c, only the number of laminated flat steel plates 12 of the intermediate laminate 21b located in the middle of the arrangement direction of the intermediate laminate 21 is the other intermediate More than the number of stacked bodies 21a and 21c are stacked.

  FIG. 2 shows an upper open state before the sandwich laminate 22b is arranged at the upper ends of the intermediate laminates 21a, 21b, and 21c.

  In the upper open state, the coil 3 wound in an annular shape is mounted in the coil accommodating spaces 30 on both sides of the intermediate intermediate laminate 21b from above. Since the welding transformer 100 according to the present embodiment is an outer iron type, an intermediate intermediate laminate 21 b is arranged in the coil 3, and intermediate laminates 21 a and 21 c at both ends are arranged around the coil 3.

  A current flows through the coil 3, and a large current necessary for welding is induced by the magnetic circuit of the laminated core 2. For the coil 3, for example, a coated conductor such as an annealed copper wire having an insulating coating is used.

  In general, the coil 3 of the welding transformer 100 includes a primary coil 31 that forms an input-side primary circuit and a secondary coil 32 that forms an output-side secondary circuit (see FIG. 3). The primary coils 31 and the secondary coils 32 are alternately arranged and are wound around the intermediate intermediate laminate 21b in an annular shape. In FIG. 3, reference numeral 33 denotes a secondary coil connection terminal.

  After the coil 3 is mounted around the intermediate intermediate laminate 21b, the sandwich laminate 22b is disposed on the upper ends of the intermediate laminates 21a, 21b, and 21c, and the coil housing space 30 is closed. That is, the intermediate laminates 21a, 21b, and 21c are sandwiched between a pair of sandwich laminates 22a and 22b that face each other from both sides in the length direction of the intermediate laminates 21a, 21b, and 21c. Therefore, the distance between the pair of sandwiched laminates 22a and 22b is determined by the length of the intermediate laminates 21a, 21b, and 21c.

  In order to reduce the leakage magnetic flux between the intermediate laminates 21a, 21b, and 21c and the sandwich laminates 22a and 22b, the both ends of the intermediate laminates 21a, 21b, and 21c are held in contact with each other. The contact surfaces of the stacked bodies 22a and 22b are in surface contact.

  As shown in FIG. 3, the front and rear ends in the width direction of the sandwiched laminates 22 a and 22 b and the intermediate laminates 21 a and 21 c are sandwiched by a pair of assembly flanges 41 and 42. These assembly flanges 41 and 42 have a window (not shown) for projecting the coil 3 to the outside at the center, and a bolt hole (not shown) for inserting the bolt 43 around the periphery.

  The bolts 43 are inserted into the bolt holes facing each other in the assembly flanges 41 and 42, and nuts 44 are attached to the respective bolts 43, whereby the laminated core 2 is fixed between the assembly flanges 41 and 42.

  As the bolt 43, a normal bolt having one end threaded may be used, but a stud bolt having both ends threaded is preferably used. Even if the bolt rotates in one direction due to vibration caused by electromagnetic induction during welding, the stud bolt tries to loosen the nut at one end but tries to tighten the nut at the other end. This is because loosening is difficult to occur.

  As described above, in the laminated core 2 of the welding transformer 100 according to the first embodiment, the width of the flat steel plate 12 forming the intermediate laminated body 21 and the width of the flat steel plate 12 forming the sandwich laminated body 22 are the same width. Is set to Therefore, it is not necessary to change the setting of the punching width of the press machine between the intermediate laminate 21 and the sandwich laminate 22, and the number of cutting steps of the flat steel plate 12 can be reduced.

  Moreover, the width direction of the intermediate | middle laminated body 21 and the clamping laminated body 22 is aligned in the same direction. On the other hand, in the front view of FIG. 1A, the length direction of the intermediate laminated body 21 faces the height direction HL of the laminated core 2, and the length direction of the sandwich laminated body 22 faces the left-right direction LR of the laminated core 2. The length direction of the intermediate laminate 21 and the sandwich laminate 22 intersects. Therefore, the coil accommodating space 30 for accommodating the coil 3 is defined by the combination of the planes of the intermediate laminates 21a, 21b, 21c and the sandwich laminates 22a, 22b.

  On the other hand, in the structure of the conventional laminated iron core, the laminating direction of all flat steel sheets is oriented in the front-rear direction FR of the laminated iron core, and the coil housing space 30 is partitioned by the laminated end faces of the flat steel sheets.

  Therefore, the number of sheets (the number of sheets used) of the flat steel plates 12 in this embodiment is smaller than that of a conventional laminated core. Therefore, even if the laminated core 2 is adopted, the number of cutting steps and the number of laminated sheets of the flat steel plates 12 can be reduced, the assembly work time of the laminated core 2 can be shortened, and the manufacturing cost of the welding transformer 100 can be reduced. it can.

  Moreover, since the intermediate | middle laminated body 21 and the sandwiching laminated body 22 are arrange | equalized with the same width | variety, the material cutting of the flat steel plate 12 for intermediate | middle laminated bodies and the sandwiching laminated body is possible from the flat steel plate of one kind of width. In addition, since it is not necessary to prepare a plurality of flat steel plates 12 having different widths, the cost of replacement in the cutting process and the stock cost of the flat steel plates 12 are reduced.

  Furthermore, the iron core structure of the welding transformer 100 of the present embodiment is a laminated iron core 2 and requires equipment such as a winding machine, a heat treatment tank, an adhesive impregnation furnace, and a wound core cutting machine like a wound core and a cut core type iron core. Therefore, the capital investment is kept low and a large site area is unnecessary.

[Embodiment 2]
In the second embodiment, the welding transformer according to the present invention is applied to an inner iron type welding transformer in which a coil is arranged around a laminated iron core.

  With reference to FIG. 4 and FIG. 5, the welding transformer 200 of Embodiment 2 is demonstrated. FIG. 4 is a front view and a side view showing the laminated core of the welding transformer of the first embodiment. FIG. 5 is a plan view illustrating a state in which the upper part of the welding transformer according to the second embodiment is open. In addition, about the same component as Embodiment 1, it attaches | subjects and demonstrates the same code | symbol.

  As shown in FIGS. 4 and 5, the welding transformer 200 according to the second embodiment is an inner iron type. Therefore, between the pair of sandwiched laminates 22 a and 22 b, 2 The set intermediate laminates 21a and 21c are arranged. The welding transformer 200 according to the second embodiment is different from the first embodiment in that no intermediate intermediate laminate is provided between the intermediate laminates 21a and 21c at both ends.

  The intermediate laminates 21a and 21c are arranged with an interval for arranging the coils 3 and 3 and the lengths of the intermediate laminates 21a and 21c are aligned. A coil 3 is wound around the intermediate laminates 21a and 21c in an annular shape.

  The width directions of the intermediate laminates 21a and 21c and the sandwich laminates 22a and 22b are aligned in the same direction. And a pair of clamping laminated bodies 22a and 22b are clamping these intermediate | middle laminated bodies 21a and 21c from the both sides of each length direction similarly to Embodiment 1. FIG.

  The welding transformer 200 of the second embodiment has one coil housing space 30 between the intermediate laminated bodies 21a and 21c at both ends. In the front view of FIG. 4A, the length direction of the intermediate laminated body 21 faces the height direction HL of the laminated iron core 2, and the length direction of the sandwich laminated body 22 faces the left-right direction LR of the laminated iron core 2. The length direction of the intermediate laminate 21 and the sandwich laminate 22 intersects. Therefore, the coil accommodating space 30 for accommodating the coil 3 is defined by the combination of the planes of the intermediate laminates 21a, 21b, 21c and the sandwich laminates 22a, 22b.

  As a result, in FIG. 4A, the lamination direction of the intermediate laminates 21a and 21c is directed in the left-right direction LR of the laminated core 2, and the lamination direction of the sandwich laminates 22a and 22b is directed in the height direction HL of the laminated core 2. It will be. Therefore, the number of laminated flat steel plates 12 (the number of sheets used) can be reduced as compared with the prior art, and the number of cutting steps can be reduced.

  Further, in the welding transformer 200 of the present embodiment, the intermediate laminate 21 and the sandwich laminate 22 are set to have the same width in order to reduce the number of cutting steps of the flat steel plate 12 as in the first embodiment.

  And the inner iron type welding transformer 200 of this embodiment is assembled using a pair of assembly flanges 41 and 42 which have a window and a bolt hole, the bolt 43, and the nut 44 similarly to Embodiment 1. FIG.

  As described above, the welding transformer 200 according to the second embodiment has the same basic structure as that of the first embodiment, and thus has the same effects as those of the first embodiment.

[Embodiment 3]
In the third embodiment, the welding transformer manufacturing method according to the present invention is applied to the outer iron type welding transformer of the first embodiment.

  FIG. 6 is a flowchart of a method for manufacturing a welding transformer in the third embodiment. In addition, this flowchart shows the manufacturing procedure of the manufacturing method of a welding transformer.

  As shown in FIG. 6, in the manufacturing method of Embodiment 3, as a preparation stage, a plurality of rectangular flat steel plates 12 having the same width and length are prepared (S1). The flat steel plate 12 is formed by punching a steel plate using a press.

  In the present embodiment, since the intermediate laminate 21 and the sandwich laminate 22 are aligned with the same width, it is possible to cut out the material of the flat laminate 12 for the intermediate laminate and the sandwich laminate from a single type of steel plate. . Further, if the intermediate laminate 21 and the sandwich laminate 22 are made to have the same width, it is not necessary to prepare a plurality of flat steel plates 12 having different widths. Cost is reduced.

  When the intermediate laminated body 21 and the sandwich laminated body 22 are laminated, the plurality of punched flat steel sheets 12 are immersed in an insulating solvent such as a natural resin compound such as varnish or a synthetic resin so that the steel sheet surface is insulated and coated. The

  Next, before the insulating solvent solidifies, the flat steel plates 12 are laminated in the thickness direction to form a plurality of intermediate laminates 21 and a plurality of sandwich laminates 22 (S2). If the flat steel plates 12 are laminated before the insulating solvent is solidified, the flat steel plates can be bonded to each other. In the present embodiment, three sets of intermediate laminates 21a, 21b, and 21c and a pair of sandwich laminates 22a and 22b are formed.

  The intermediate laminate 21 and the sandwich laminate 22 may have the same or different number of flat steel plates 12 stacked. In the present embodiment, among the intermediate laminates 21a, 21b and 21c, the number of intermediate laminates 21b positioned in the middle of the arrangement direction of the intermediate laminate 21 is greater than the number of laminates of the intermediate laminates 21a and 21c at both ends. It is increasing.

  Next, the width directions of the intermediate laminates 21a, 21b, 21c and the sandwich laminates 22a, 22b are aligned in the same direction (S3). In the present embodiment, the width direction of the intermediate laminate 21 and the sandwich laminate 22 is aligned with the front-rear direction FR of the laminate core 2 as shown in FIG.

  Further, the intermediate laminates 21a, 21b, and 21c are arranged with the length of the intermediate laminate 21 being aligned and spaced according to the number of turns of the coil 3 (S4). In the present embodiment, the length direction of the intermediate laminates 21 a, 21 b, and 21 c is aligned with the height direction HL of the laminated core 2. The intermediate laminates 21a, 21b, and 21c having the same length direction are arranged on one sandwich laminate 22a with an interval for mounting the coil 3 therebetween.

  By arranging in this way, as shown in FIG. 1 (a), the three sets of intermediate laminates 21a, 21b, 21c stand upright perpendicularly to both ends and the middle in the length direction of the sandwich laminate 22. Become. The arrangement direction of the intermediate laminate 21 matches the length direction of the sandwich laminate 22 and the left-right direction LR of the laminate core 2.

  In addition, when manufacturing the welding transformer 200 of Embodiment 2, the intermediate | middle laminated bodies 21a and 21c are two sets. Since the welding transformer 200 of the second embodiment is an inner iron type, two sets of intermediate laminates 21 a and 21 c are disposed at both ends in the length direction of the sandwich laminate 22.

  And the coil 3 is arrange | positioned in the coil accommodation space 30 of the both sides of the intermediate | middle laminated body 21b (S5). In the coil 3, the primary coil 31 on the input side and the secondary coil 32 on the output side are alternately arranged, and are wound in an annular shape along the length direction of the intermediate laminate 21.

  Thereafter, the upper sandwiched laminate 22b is disposed on the upper ends of the intermediate laminates 21a, 21b, and 21c, and sandwiched by the pair of sandwich laminates 22a and 22b from both sides in the length direction of the intermediate laminate 21 (S6). The clamping by the sandwiched laminates 22a and 22b is performed using a pressing jig (not shown).

  That is, by sandwiching the intermediate laminates 21a, 21b, and 21c with the pair of sandwich laminates 22a and 22b, pressing the intermediate laminate 21 from both sides in the length direction using a pressing jig, the sandwich laminate laminate Intermediate laminates 21a, 21b, and 21c are fixed between 22a and 22b. The pressing jig is used so that the both end surfaces in the length direction of the intermediate laminates 21a, 21b, and 21c and the contact surfaces of the sandwich laminates 22a and 22b that are in contact with the both end surfaces are surely brought into surface contact. This is to reduce the leakage magnetic flux between the laminate 21 and the sandwich laminate 22.

  Finally, the intermediate laminates 21a and 21c and the sandwich laminates 22a and 22b are sandwiched by the pair of assembly flanges 41 and 42 from both sides in the width direction of the intermediate laminate 21 and the sandwich laminate 22 (S7). As described above, these assembly flanges 41 and 42 have a window (not shown) for projecting the coil 3 to the outside at the center, and a bolt hole (not shown) for inserting the bolt 43 around.

  The clamping by the pair of assembly flanges 41 and 42 is such that the assembly flanges 41 and 42 face each other in the state in which the intermediate laminates 21a and 21c and the sandwich laminates 22a and 22b are sandwiched by the assembly flanges 41 and 42. Each of the bolts 43 is passed through and a nut 44 is attached to each bolt 43. In this embodiment, a stud bolt is employed as the bolt 43 in order to give a strong holding force to the assembly flanges 41 and 42 even if vibration occurs in the welding machine.

  In the manufacturing method according to the third embodiment, the intermediate laminate 21 and the sandwich laminate 22 are aligned with the same width. Therefore, it is possible to cut out the material of the flat steel plate 12 for the intermediate laminate and the sandwich laminate from a single type of steel plate. In addition, since it is not necessary to prepare a plurality of flat steel plates 12 having different widths, the cost of replacement in the cutting process and the stock cost of the flat steel plates 12 are reduced.

  Furthermore, the manufacturing method of embodiment can manufacture the laminated iron core 2 using a simple jig | tool. Therefore, unlike winding cores and cut core type cores, equipment such as winding machines, heat treatment tanks, adhesive impregnation furnaces and winding core cutting machines are not required, and capital investment can be kept low, and a large site area is not required. is there.

  The preferred embodiments of the present invention have been described above, but these are examples for explaining the present invention, and the scope of the present invention is not intended to be limited to these embodiments. The present invention can be implemented in various modes different from the above-described embodiments without departing from the gist thereof.

  For example, in Embodiment 1 and Embodiment 2 described above, the intermediate laminate 21 and the sandwich laminate 22 are all aligned with the same width, but the width of the intermediate laminate 21 accommodated in the coil 3 is the sandwich laminate 22. You may set smaller than the width | variety. By setting the width of the intermediate laminate 21 accommodated in the coil 3 to be small, the degree to which the coil 3 protrudes from the assembly flanges 41 and 42 is reduced, or the coil 3 is accommodated in the assembly flanges 41 and 42. Can be.

<Example>
Hereinafter, the welding transformer according to the present invention will be described in more detail with reference to examples and comparative examples, but the present invention is not limited to the examples.

〔Example〕
With reference to FIG. 1 again, an embodiment of a welding transformer according to the present invention will be described. In this embodiment, the laminated core 2 shown in FIG. 1 was assembled.

  As described above, in the laminated core 2 of the embodiment, the coil housing space 30 is defined by the planes of the intermediate laminated bodies 21a, 21b, and 21c and the sandwiched laminated bodies 22a and 22b. Therefore, the lamination direction of the intermediate laminated bodies 21a, 21b, and 21c is directed in the left-right direction LR of the laminated iron core 2, and the laminated direction of the sandwich laminated bodies 22a and 22b is oriented in the height direction HL of the laminated iron core 2.

  The plate thickness of the flat steel plate 12 used in the present embodiment is 0.5 mm. The stack thickness of the stack 20 is 120 mm (240 stacks) only for the stack thickness of the intermediate stack 23b located in the middle of the arrangement direction of the intermediate stack 21 among the plurality of intermediate stacks 21a, 21b, 21c. The laminate thickness of the other laminates 21a, 21c, 22a, and 22b was set to 60 mm (120 laminates). As a result, the total number of used flat steel plates 12 was 240 + 120 × 4 = 720.

[Comparative Example]
Next, a welding transformer having a conventional structure will be described as a comparative example with reference to FIG. FIG. 7 is a front view and a side view showing a laminated iron core of a welding transformer of a comparative example, which is shown corresponding to FIG.

  In the comparative example, the laminated core 52 was assembled as shown in FIG. In the laminated core 52 of the comparative example, the coil housing space 30 is defined by the laminated end surfaces of the intermediate laminated bodies 61a, 61b, 61c and the sandwich laminated bodies 62a, 62b. Therefore, the stacking directions of the intermediate stacked bodies 61 a, 61 b, 61 c and the sandwiched stacked bodies 62 a, 62 b are all directed to the front-rear direction FR of the stacked core 52.

  The plate thickness of the flat steel plate used in the comparative example is 0.5 mm as in the example. The stack thickness of the stack 60 was 325 mm (650 stacks) for the intermediate stacks 61a, 61b, 61c and the sandwich stacks 62a, 62b. The number of the laminated bodies 60 is 5 sets like the embodiment. As a result, the total number of used flat steel plates 12 was 5 × 650 = 3250.

  Thus, the laminated iron core 2 of an Example can reduce significantly the total number of the flat steel plates 12 to be used compared with the conventional structure. That is, although the said Example can employ | adopt the laminated iron core 2, the cutting man-hour and the number of lamination | stacking of the flat steel plate 12 can be reduced significantly, the assembly operation time of the laminated iron core 2 can be shortened, and the welding transformer 100 can be reduced. The manufacturing cost can be reduced.

  The welding transformer according to the present invention can be widely applied to welding machines such as spot welding machines and laser welding machines used for assembling vehicles such as automobiles and railway vehicles.

3 coils,
12 flat steel sheet,
21 (21a, 21b, 21c) intermediate laminate,
22 (22a, 22b) sandwich laminate,
100, 200 Welding transformer.

Claims (8)

A plurality of intermediate laminates in which a plurality of rectangular flat steel plates having the same width and length are laminated in the thickness direction of the flat steel plates;
A plurality of sandwich laminates in which rectangular flat steel plates having the same width as the intermediate laminate are laminated in the thickness direction of the flat steel plates;
The width direction of the intermediate laminate and the sandwich laminate is aligned in the same direction,
The plurality of intermediate laminates are arranged with an interval between them so as to align the length direction of the intermediate laminate,
A coil is wound around the intermediate laminate in an annular shape,
The plurality of sandwich laminates sandwich the plurality of intermediate laminates arranged from both sides in the length direction of the intermediate laminate,
The intermediate laminate and the sandwich laminate are sandwiched by a pair of assembly flanges from both sides in the width direction of the intermediate laminate and the sandwich laminate ,
The pair of assembly flanges have a plurality of bolt holes around them, and the intermediate laminate and the sandwich laminate are clamped by bolts and nuts passed through the bolt holes .   The intermediate laminate and the sandwich laminate are in contact with each other in the lengthwise direction of the intermediate laminate and the contact surfaces of the sandwich laminate in contact with both end faces are the intermediate laminate and the sandwich laminate. The welding transformer according to claim 1, wherein surface contact is made to reduce leakage magnetic flux between the two.   The welding transformer according to claim 1 or 2, wherein the number of laminated flat steel sheets of the intermediate laminated body and the sandwich laminated body is different. The coil welding transformer according to any one of claims 1 to 3, wherein Rukoto provided in the intermediate stack which is located in the middle of the direction of arrangement of said plurality of intermediate laminates. The welding transformer according to any one of claims 1 to 3 , wherein the coil is provided in two intermediate laminates positioned at both ends of the arrangement direction in the plurality of intermediate laminates. Preparing a plurality of rectangular flat steel plates having the same width and length;
Laminating the flat steel plates in the thickness direction of the flat steel plates to form a plurality of intermediate laminates and a plurality of sandwich laminates;
The width direction of the intermediate laminate and the sandwich laminate is aligned in the same direction, the plurality of intermediate laminates are arranged with the length direction of the intermediate laminate being aligned, and the intermediate laminate is annularly arranged. Arranging the wound coil, and sandwiching the plurality of arranged intermediate laminates with the plurality of sandwich laminates from both sides in the length direction of the intermediate laminate;
Clamping the intermediate laminate and the sandwich laminate with a pair of assembly flanges from both sides in the width direction of the intermediate laminate and the sandwich laminate, and
The step of sandwiching between the pair of assembly flanges includes:
A method of manufacturing a welding transformer, wherein a bolt is passed through a plurality of bolt holes provided around the pair of assembly flanges, and a nut is attached to the bolt to sandwich the intermediate laminate and the sandwich laminate. . The step of preparing the flat steel plate includes:
7. The method of manufacturing a welding transformer according to claim 6, wherein a plurality of rectangular flat steel plates having the same width and length are prepared by punching the steel plates with a press . The step of sandwiching with the plurality of sandwich laminates includes:
Using a jig that presses the sandwich laminate from both sides in the length direction of the intermediate laminate, the plurality of intermediate laminates are sandwiched by the plurality of sandwich laminates from both sides in the length direction of the intermediate laminate. The manufacturing method of the welding transformer of Claim 6 or 7 characterized by the above-mentioned.

Images