JPH01117007A - Electromagnetic apparatus and its manufacture - Google Patents

Abstract

PURPOSE:To make both junction surfaces completely coincide with each other, make them bring into close contact with each other, and prevent the generation of noise, by constituting a laminated core by a center leg core and a side leg core, and constituting junction surfaces of the center leg core and those of the side leg core by the same blanking surfaces. CONSTITUTION:A laminated core 2 has a structure wherein a center leg core 4 and a side leg core 5 are blanked and separated. The core 4 has a structure wherein laminated plates 4a are stacked by a linking means 8. The laminated plates 4 have central leg junction surfaces 6 constituted of blanking surfaces with the core 5, and path parts 7. The core 5 is constituted of a first side leg core 11 and a second side core leg 12, and a bottom plate core 13 is formed at the bottom. The core 11 has an aperture to accommodate the core 4 and a coil 3, and is formed by a laminated plate 11a having side leg junction surfaces 16. The core 12 is provided with an aperture 14, and has a constitution wherein a laminated plates 12a is stacked in thickness almost corresponding to the winding thickness of a coil.

Description

DETAILED DESCRIPTION OF THE INVENTION [Object of the Invention] (Industrial Field of Application) The present invention relates to electromagnetic equipment such as discharge lamp ballasts, transformers, and reactors, and methods of manufacturing the same.

(Prior Art) An electromagnetic device consists of a laminated core that includes a central leg and side legs and forms a closed magnetic circuit, and a coil that is wound around and attached to the central leg of the laminated core. for,
A coil is wound around the central leg, but if the laminated core that forms the closed magnetic circuit is formed integrally in advance, it is very troublesome to wind the coil around the central leg. After winding a coil around the central leg of the E-shaped core, the I-shaped core is joined to the E-shaped core, for example, a tightening band, a tightening cap, or a side leg of the F-shaped core and the ■-shaped core. It is integrated by welding along the laminated outer surface of the abutting surface. In addition to the above-mentioned combination of E-type core and I-type core, methods of dividing the laminated core include combining a pair of E-type cores, or combining E-type cores on both sides of a ■-type core. There are also such things.

(Problems to be Solved by the Invention) As mentioned above, the laminated core is divided into, for example, an E-shaped core and a ■-shaped core so that coils can be wound easily, and these are joined by tightening bands or welding. The central leg of the E-shaped core is joined to the I-shaped core by butt, but since the joint surface of the central leg of the E-shaped core and the joint surface of the I-shaped core are stamped separately, Not only are the shapes difficult to match, but it is also difficult to join both joining surfaces uniformly due to variations in the joining state due to tightening bands, etc., and the joining of the central leg and side legs is caused by magnetic vibration when the coil is energized. The parts were likely to resonate, producing noise, and the magnetic properties were likely to deteriorate.

In addition, most of the heat generated by the coil when energized is dissipated through the laminated core, so heat dissipation can be improved by, for example, increasing the surface area by thickening the laminations of the laminated core. In a laminated core that is separated into an E-type core and an I-type core, the center leg of the E-type core is inserted inside the coil, so the lamination thickness of the E-type core and I-type core is determined by the lamination thickness of the center leg. Therefore, it was not possible to improve heat dissipation by increasing the thickness of the side legs.

Furthermore, the lamination of the laminated core requires a tightening band or the like, or requires welding in a separate process.

The present invention has been made in view of the above-mentioned points, and even if the center leg core and the side leg cores are separated so that the coil can be easily wound, the connection between the center leg core and the side leg cores can be prevented. The purpose is to provide electromagnetic equipment that can match the shape of the surfaces, prevent noise, improve magnetic properties, and improve heat dissipation. Without stacking and connecting by welding etc. in the process,
The object of the present invention is to provide a method for manufacturing electromagnetic equipment that can be laminated and connected in a laminated core punching process.

[Structure of the invention]

(Means for Solving the Problems) The present invention provides an outer iron type electric IIII device comprising a laminated core and a coil mounted on the laminated core, in which the laminated core is wound with the coil. A center leg core and a side leg core are separated, and the side leg core has a side leg joint surface formed of a punched surface obtained by punching out the center leg core, and is laminated in correspondence with the lamination of the center leg core. A first side leg core made of the above-mentioned side leg core and a second side leg core formed without the above-mentioned side leg joint surface and laminated to a lamination thickness approximately corresponding to the winding thickness of the coil are integrally laminated, and , the central leg core is configured with a punched surface with the first side leg core, and when assembled with the side leg core, the first side leg core
The central leg joint surface is connected to the side leg joint surface of the side leg core.

Further, the present invention comprises a laminated core and a coil attached to the laminated core, and the laminated core separates a central leg core and a side leg core around which the coils are wound, and the side leg core is located at the center. A 10th side leg core is laminated in correspondence with the lamination of the central leg core, and the tenth side leg core is provided with a side leg joint surface formed of a punched surface of the leg core, and a second side leg is not provided with a side leg joint surface. The cores are integrally laminated to a layer thickness approximately equivalent to the winding thickness of the coil, and the medium-heat leg core is configured with a punched surface with the first side leg core, and when assembled with the side leg core, A method for manufacturing an electromagnetic device in which a first side leg core has a center leg joint surface that is joined to a side leg joint surface of the first side leg core and is laminated in correspondence with the lamination of the first side leg core, the method comprising: The laminated blank plate from which each laminated plate of the iron core is punched out is provided with caulking uneven portions corresponding to the inner positions of the laminated plates, and in the process of punching each laminated plate from this laminated blank plate, each laminated plate is stamped. The laminated plates are laminated and connected to each other by fitting the concave and convex portions for caulking between the laminated plates.

(Function) In the present invention, by constructing the joint surfaces of the center leg iron core and the joint surfaces of the side leg irons with the same punched surface, the joint shapes of the two joint surfaces completely match, and the joint surfaces are firmly attached to each other during assembly. moreover,
The laminated core has a larger heat capacity and a larger surface area by the amount of lamination of the second side leg core.

Further, by providing caulking uneven portions before punching out the center leg core, side leg cores, etc. from the laminated blank plate, the center leg core, side leg cores, etc. are laminated and connected together with the punching in the punching process.

(Example) Hereinafter, the configuration of an example of the present invention will be described with reference to the drawings.

In FIGS. 1 to 5, reference numeral 1 denotes an electromagnetic equipment body such as a discharge lamp ballast, which is composed of a laminated iron core 2 and primary and secondary coils 3.

The laminated core 2 has a structure in which a center leg core 4 and a side leg core 5 are separated by punching.

This center leg core 4 has a convex center leg joining surface 6 formed of a punched surface with the side leg core 5 on both end surfaces, and a plurality of laminated plates 4a having a pass portion 7 approximately at the center of both sides, which will be described later. They are formed by being stacked and connected by a connecting means 8.

Further, the side leg core 5 has a first side leg core 11 and a second side leg core 11.
and a side leg core 12, and a bottom plate core 13 is laminated and connected to the bottom to form a bottomed pot shape. The first side leg core 11 has a rectangular opening 14 for housing the center leg core 4 and the coil 3 inside, and the yoke 1
An annular laminated plate 11a having a concave side leg joint surface 16 formed from a punched surface obtained by punching out the FI layer plate 4a of the central leg core 4 is laminated on the inside of the central leg core 4 in correspondence with the lamination of the central leg core 4. However, the second side leg iron core 12 has an annular laminated plate 12a having an opening 14 on the inside and no side leg joint surface 16 on the inside of the yoke part 15, which are laminated to a thickness of 30 turns or more of the coil. Furthermore, the bottom plate core 13 is formed by laminating a plurality of laminated plates 13a formed in a flat plate shape. And the laminated plates 11a and 12
a and the laminated plate 13a are laminated and connected by a connecting means 8.

As shown in FIG. 4, the connecting means 8 of the central leg core 4 is provided with a circular caulking hole 21 in the laminated plate 4a of the lowest layer, and a caulking uneven portion 22 in the laminated plate 4a of the upper layer than the lowest layer. has been established. This caulking uneven portion 22 is created by half punching the laminate 4a by shortening the punching stroke of the same punch that punches the caulking hole 21, and by protruding circular caulking protrusions 23 on the lower side and on the upper side. A circular caulking recess 24 is provided. Then, the caulking protrusions 23 of the laminated plate 4a stacked above are press-fitted into the caulking holes 21 of the lowermost laminated plate 4a, and the caulking protrusions 23 of the laminated plate 4a of the lower layer are further inserted into the caulking recesses 24 of the lower laminated plate 4a. Laminated plate 4a to be laminated
By press-fitting the caulking projections 23, the laminated plates 4a are laminated and connected to each other. The connecting means 8 of the side leg core 5 also has the same structure, and a caulking hole 21 is provided in the laminated plate 13a of the bottom plate core 13 in the lowermost layer, and uneven portions 22 for caulking are provided in the laminated plates 13a, 12a, and 11a in the upper layer.
are installed and connected in layers.

Then, the manufacturing process of the laminated core 2 will be explained with reference to FIG. 6. In the manufacturing process, pilot holes 27 are formed at predetermined intervals in the strip-shaped laminated blank 26 corresponding to the four corners of the side leg core 5. In the B process, the caulking hole 21 or the caulking uneven part 22 is machined, and in the C process, the laminated plate 4a of the central leg core 4 is punched out and pushed into the mold of the die. In the DI step, the caulking hole 21 or caulking uneven portion 22 of the side leg core 5 is processed, in the E process, the opening 14 of the side leg core 5 is punched, and in the FT step, the side leg core 5 is blank punched. It is designed to be pushed into the mold of the die.

First, the portion of the laminated blank 26 that serves as the first reference between the pilot holes 27 that have been continuously machined at predetermined intervals in the F process passes through B and C processes, and caulking holes 11 are punched out in the DI process. The laminated plate 13a of the bottom plate core 13, which is processed and passed through the E step, and is formed by blank punching in the F step, is pushed into the mold of a die. In the portion of the laminated blank 26 between the next pilot holes 27, the concave and convex portions 22 for caulking of the bottom plate iron core 13 are processed in the DI stage, and the laminated plate 13a formed by blank punching in the FT stage is placed in the mold of the die. The caulking protrusions 23 are press-fitted into the caulking holes 21 of the previously punched laminate plate 13a, and the laminated plates 13a are mutually laminated and connected. Thereafter, similar steps are performed for the number of laminated plates 13a of the bottom plate core 13.

The next part of the laminated blank 26 that has been punched out as the bottom plate core 13 passes through steps B and C, and at the DI stage, the uneven portion 22 for caulking is formed.
The laminated plate 12a of the second side leg core 12 formed by punching out the opening 14 in the E process and blank punching in the F process is pushed into the mold of the die, and the bottom plate core 13 is pressed into the die.
They are laminated and connected via the caulking uneven portion 22 on top. Thereafter, similar steps are performed for the number of laminated plates 12a of the second side leg core 12.

The next laminated blank plate 26 punched as the second side leg core 12
In the DI stage, the caulking hole 21 of the center leg core 4 is machined, and the laminated plate 4a formed by punching out the shape of the center leg core in the C process is pushed into the mold of the die, and in the DI stage. The caulking unevenness 22 of the first side leg core 11 is processed, the opening 14 of the first side leg core 11 is punched in the E step, and the blank is punched out in the FI step to form the laminated plate 11a. It is pushed into the mold of the die, and is laminated and connected on the second side leg core 12 via the caulking uneven portion 22. Furthermore, the portion of the laminated blank plate 26 between the next pilot holes 27 is a laminated plate formed by processing the caulking uneven portion 22 of the center leg core 4 in the DI step and punching it into the shape of the center leg core in the C step. 4a is pushed into the mold of the die, and the caulking protrusion 23 is press-fitted into the caulking hole 21 of the previously punched laminated plate 4a to connect the laminated plates to each other, and this laminated plate 4a is punched out. 26 is processed in the D-F process as described above. Thereafter, similar steps are performed for the number of laminated plates 4a of the center leg core 4 and the number of laminated plates 11a of the first side leg core 11.

Note that the punch used to process the caulking hole 21 and caulking irregularities 22 in the DI process and the DI process has a structure that allows the punching stroke to be varied, and each process from B to E is automatically performed using a counting counter. controlled.

In this way, the laminated plate 4a and the laminated plates 13a, 12a, and 11a are punched out from the laminated blank 26, and in the punching process, the central leg core 4 and the side leg cores 5 are laminated, and the caulking hole 21 and the caulking irregularities are formed. They can be stacked and connected via 22.

Then, as shown in FIGS. 2 and 3, the primary and secondary coils 3 wound around the coil bobbin 31 are attached to both ends of the center leg core 4, and the center leg of the center leg core 4 is By aligning and press-fitting the joining surface 6 to the side leg joining surface 16 of the side leg core 5 from above, the central leg core 4 and the coil 3 are housed inside the opening 14 of the side leg core 5, and the electromagnetic device main body 1 is assembled. form. This central leg core 4 is connected to the side leg core 5.
In the press-fitted state, the bottom surface of the central leg core 4 abuts the upper surface of the second side leg core 12 facing from the concave joint surface 16 of the first side leg core 11, and positioning in the vertical direction is performed. At the same time, the convex joint surfaces 6 of the center leg core 4 fit into the concave joint surfaces 16 of the side leg cores 5 for lateral positioning, and each laminated plate 4a of the center leg core 4 The joint surface 6 of is joined to the joint surface 16 of each laminated plate 11a of the corresponding first side leg iron core 11 punched from the same laminated blank plate 26,
The joint shapes match perfectly and are firmly adhered. Further, a predetermined magnetic gap is formed between the laminated outer surface of the path portion 7 of the center leg core 4 and the laminated inner side of the side leg core 5.

In addition, the inside of the side leg core 5 and the coil 3 and the medium heat leg core 4
The gap between the two is filled with an electrically insulating filler 32 made of, for example, polyester resin or epoxy resin.

Furthermore, as shown in FIG. 5, the electromagnetic device main body 1, which is a combination of the laminated core 2 and the coil 3, is provided with a cover 33 that covers the coil 3 on the top surface and covers the side leg cores 5 on the bottom surface and both sides. A case 34 is attached, and the caulking claws 35 of the case 34 are caulked to the edge of the cover 33 to fix the connection. Note that there are mounting holes 36 on the bottom plate of the case 34.
is provided.

In the electromagnetic device configured as described above, by configuring the joint surface 6 of the central leg core 4 and the joint surface 16 of the side leg core 5 with the same punched surface, both joint surfaces 6° 16 have a perfect joint shape. In accordance with this, the joints between the central leg iron core 4 and the side leg iron cores 5 are prevented from resonating due to magnetic vibration when the coil 3 is energized, thereby reducing the generation of noise. Furthermore, magnetic properties can be improved.

Furthermore, since the side leg iron core 5 is annular, this side leg iron core 5
Since there is no butt part, there is no need for tightening bands or welding processes to maintain the butt state as in the past, and it is possible to prevent noise generation and deterioration of magnetic properties.
The central leg core 4 can also be firmly held.

Further, the laminated core 2 can have a larger heat capacity and a larger surface area by the amount of the second side leg core 12 and the bottom plate core 13, and can efficiently dissipate the heat generated by the coil 3.

Furthermore, by integrally laminating the bottom plate core 13 on the side leg core 5 to form a pot shape, the gap between the inside of the side leg core 5 and the coil 3 and center leg core 4 can be maintained without the need for sealing means. can be filled with a filler 32, which can fix the side leg core 5 from the inside and also fix the coil 3 and the center leg core 4 to suppress magnetic vibration. heat can be efficiently transmitted to the laminated iron core 2.

Furthermore, by integrally laminating the bottom plate core 13 on the side leg core 5 to form a pot shape, the case 34 is not required.
It becomes possible to protect.

Furthermore, by providing the caulking holes 21 and the uneven portions 22 for caulking before punching out the center leg core 4, side leg cores 5, etc. from the laminated blank plate 26, the center leg core 4, side leg cores 5, etc. are punched out in the punching process. The leg cores 5 can be stacked and connected.

Note that the shape of the joint surface 6 of the central leg core 4 and the joint surface 16 of the side leg core 5 may be any shape as long as the joint portion 6 is convex and the joint surface 16 is concave. By forming the joint surfaces 6 and 16 of the two side pairs of the core 4 and the side leg cores 5 in different shapes, it is possible to determine the direction in which the center leg core 4 is press-fitted into the side leg core 5, thereby preventing incorrect insertion. It can be prevented.

Further, the shape of the caulking uneven portion 22 that connects the central leg core 4 and the side leg cores 5 in a stacked manner may be a substantially V-shaped protrusion,
By making the width of the protrusion larger than the thickness of the laminate, the strength of the connection between the laminates can be increased.

〔Effect of the invention〕

According to the present invention, by constructing the joint surface of the center leg iron core and the joint surface of the side leg iron cores with the same punched surface, the joint shapes of both joint surfaces completely match and the joint surfaces are firmly attached during assembly. It is possible to prevent the connecting portion between the central leg iron core and the side leg iron cores from resonating due to magnetic vibration when the coil is energized, thereby reducing noise generation and improving magnetic properties.

Furthermore, the laminated core can increase the heat capacity by the amount of lamination of the second side leg core, and can also increase the surface area, so that the heat generated by the coil can be efficiently dissipated.

In addition, by providing caulking uneven parts before punching out the center leg core, side leg cores, etc. from the laminated blank plate, the center leg core and side leg cores can be laminated and connected together with the punching during the punching process. , it is possible to omit tightening caps and welding processes for stacking and connecting.

[Brief explanation of the drawing]

Fig. 1 is a perspective view of a laminated core showing an embodiment of the electromagnetic equipment and method for manufacturing the same according to the present invention, Figs. 2 and 3 are sectional views of the electromagnetic equipment, and Fig. 4 is a part of the central leg core. Figure 5 is a perspective view of electromagnetic equipment, Figure 6 is a laminated iron core! FIG. 2 is an explanatory diagram showing a manufacturing process. 2...Laminated core, 3...Coil, 4...Central leg core, 4
a...Laminated plate, 5...Side leg iron core, 6...Central leg joint surface,
11...First side leg iron core, 11a...Laminated plate, 12...
・Second side leg core, 12a...Laminated plate, 13...Bottom plate core, 16...Side leg joint surface, 22...Irregularities for caulking,
26... Laminated base plate. , < Country

Claims (3)

[Claims] (1) In an external iron type electromagnetic device consisting of a laminated core and a coil attached to the laminated core, the laminated core is
A center leg core and a side leg core around which the coil is wound are separated, and the side leg core has a side leg joint surface formed of a punched surface punched out from the center leg core, and the center leg core is laminated. A first side leg core that is laminated in correspondence to the above and a second side leg core that does not have the side leg joint surface and is laminated to a layer thickness approximately corresponding to the winding thickness of the coil are integrated. The center leg core is configured with a punched surface with the first side leg core, and the center leg joint surface is joined to the side leg joint surface of the first side leg core when assembled with the side leg core. An electromagnetic device characterized by being equipped with. (2) The side leg core of the laminated core is integrally laminated with a second side leg core formed by laminating the first side leg core with a thickness equal to or greater than the coil winding thickness, and at least one bottom plate that closes the bottom surface. An electromagnetic device according to claim 1, characterized in that the iron core is integrally laminated to form a bottomed pot shape. (3) Consisting of a laminated core and a coil attached to the laminated core, the laminated core separates the center leg core and the side leg cores around which the coils are wound, and the side leg cores separate the center leg core from the center leg core. a first with a side leg joint surface consisting of a punched punching surface;
The side leg iron cores are laminated in correspondence with the lamination of the central leg core, and the second side leg iron core, which does not have a side leg joint surface, is integrally laminated to a lamination thickness approximately equivalent to the winding thickness of the coil, and , the center leg core is configured with a punched surface with the first side leg core, and includes a center leg joint surface that joins to a side leg joint surface of the first side leg core when assembled with the side leg core. A method for manufacturing an electromagnetic device in which layers are laminated in correspondence with the lamination of the side leg cores in step 1, the method comprising: stamping and forming each of the laminates of the center leg core and the side leg cores on a laminated base plate at an inner position of each of the laminates; Correspondingly, uneven parts for caulking are provided, and in the process of punching out each laminate from this laminated blank, each laminate is laminated, and the stacked laminates are mutually laminated by fitting the uneven parts for caulking. A method for manufacturing electromagnetic equipment that is connected.