JPH0567047B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Technical Field of the Invention] The present invention relates to a method for manufacturing a one-turn cut type wound core using an amorphous magnetic ribbon.

[Technical background of the invention]

Conventionally, grain-oriented silicon steel strip has been generally used as the core material for wound core transformers, but recently amorphous magnetic ribbon, which is completely different from the core material, has been used as the core material for wound core transformers. It is being considered for use as a This amorphous magnetic ribbon has excellent magnetic properties with significantly lower core loss and excitation current than conventional silicon steel strips, and is very suitable as a core material for wound iron cores.

[Problems with background technology]

However, due to the manufacturing method, the amorphous magnetic ribbon cannot be manufactured to the same thickness as the conventional silicon steel strip, and its thickness is approximately It is extremely thin at 1/10th the thickness, and is also extremely fragile.
Therefore, when manufacturing a wound core using an amorphous magnetic ribbon, a so-called uncut type wound core having no joints, in which the amorphous magnetic ribbon is continuously wound, is often used. . However, since the amorphous magnetic strip is a very thin foil, even if you try to wind the core of the amorphous magnetic strip while applying the same tension as when winding the silicon steel strip, it will not work. It sometimes broke during winding, making it difficult to wind it smoothly. Therefore, when winding an amorphous magnetic ribbon, it is necessary to wind it at a relatively slow speed while controlling the tension at the time of winding to such an extent that the ribbon itself does not break. However, since the amorphous magnetic ribbon is a very thin foil as mentioned above,
It had the disadvantage that it took a considerable amount of time to wind it to a predetermined thickness.

Furthermore, in the case of a no-cut wound core, the winding must be directly wound, which makes the winding work cumbersome.Moreover, in order to improve the core occupation rate in the winding, the core cross section must be made circular. Since the stepped structure must be closely spaced, the process of manufacturing a wound core with a multi-stage configuration becomes complicated. Furthermore, the winding work involved fitting a split bobbin into the core leg and rotating it using a detachable ring gear and a drive gear to wind the wire. However, there were drawbacks such as the need to increase the height of the iron core window.

For this reason, instead of the above-mentioned no-cut method, the amorphous magnetic ribbon is sequentially cut with equal dimensions for each turn.
A one-turn cut method in which the cut iron core laminates are wound and laminated in a stepwise manner to form a plurality of laminated blocks, and the core is assembled by sequentially inserting each laminated block into the winding. A wound core has been proposed. In this case, with a relatively thick core material such as silicon steel strip, it is relatively easy to obtain excellent magnetic bonding at the joints of the wound core. However, when using an amorphous magnetic ribbon, for example,
Hereafter, based on the circumference of the innermost circumference of the iron core,
Sequentially lengthen and cut by the dimension equivalent to 2πt,
When this is rolled and laminated around a winding frame in the same way as a silicon steel strip is wound, the amorphous magnetic ribbon is a very thin foil as mentioned above, so the joints of the wound core are made of silicon. Like steel strips, it is difficult to join them in a way that maintains good magnetic properties, and undesirable air gaps may occur at the joints of the wound cores, or the ends of the core laminates that form the joints may overlap, causing the iron There were problems such as increased loss, and furthermore, the end faces of the wound layers of the wound core were uneven, and the core pieces in the uneven areas vibrated during operation of the transformer, causing noise generation. In addition, cutting amorphous magnetic ribbons one by one into required lengths and winding and stacking them one by one, as with silicon steel strips, is very inefficient in terms of manufacturing the wound core. For this reason, it has been proposed to stack a plurality of amorphous magnetic ribbons and cut them one turn at a time for winding, but this method takes less time to wind the core than the above Although it can be done quickly, since multiple core laminates are stacked and wound, if the stacked core laminates shift during winding, undesirable voids may occur at the joints of the wound core, as described above. There were various problems in producing a one-turn cut wound core using an amorphous magnetic ribbon, such as the fact that the ends of the core laminates sometimes overlapped.

[Object of the Invention] The present invention eliminates the above-mentioned drawbacks and provides a method for efficiently manufacturing a one-turn cut type wound core using an amorphous magnetic ribbon without deteriorating its characteristics. provide a method.

[Summary of the invention]

When producing a wound core using a one-turn cut method, the present invention is designed to produce a core layered plate, each unit consisting of a plurality of pieces (approximately 5 to 10 pieces) cut from amorphous magnetic ribbons of the same size, on the outermost periphery of the wound core. The core laminates of each unit are sequentially cut in equal dimensions toward the inner circumferential side, and the iron core laminates of each unit are laminated sequentially from the outermost circumferential side to form a group of laminated blocks in which a plurality of layers constitute one block, Next, the laminated block group is bent into a substantially U-shape, and both ends of each core laminate are sequentially overlapped from the inner peripheral side to form a substantially circular wound core body, and then the wound core The present invention is characterized in that the element body is formed into a rectangle and then annealed in a magnetic field to produce a one-turn cut type wound core using an amorphous magnetic ribbon.

[Embodiments of the invention]

Embodiments of the present invention will be described below with reference to FIGS. 1 to 14.

FIG. 1 shows a cutting device A for core laminates constituting each winding layer of a wound core, in which a hoop-shaped amorphous magnetic ribbon 1 (hereinafter simply referred to as a ribbon) is cut from a drum 2 by an unwinding roller 3. The iron core material 5 is fed to the position of the cutter 4 and cut into a required length by the cutting cutter 4, and the cut iron core material 5 is stored in the material storage trough 7 by the feed roller 6. When cutting the ribbon 1, an electric motor _M1 that drives the rewinding roller 3 is activated by a command signal from the control device S to rewind the ribbon 1 to the cutting cutter 4 side by a certain length. At this time, since the ribbon 1 has not been cut yet, the cutting cutter 4
does not descend, and the pressure roller 6a corresponding to the feed roller 6 also does not descend. When the ribbon 1 is rewound for a certain length, the electric motor M ₁ is stopped by a command signal from the control device S, and the unwinding of the ribbon 1 is temporarily stopped and the ribbon 1 is moved to the unwinding roller 3. , 3. On the other hand, after the electric motor _M1 is stopped, the cylinder _M3 is operated in response to a command signal from the control device S to feed the ribbon 1 and nip the roller 6 between it and the pressure roller 6a. In this state, a cutting command is sent to the cutting cutter to cut the ribbon 1. After cutting the ribbon 1, the cut iron core material 5 is sent into the material storage trough 7 by rotating the feed roller 6 by an electric motor _M2 activated by a command signal from the control device S. The length to which the core material 5 is cut is, for example, the circumference of the outermost circumference of the wound core to be manufactured as a reference, and the length is sequentially shortened by 2πt (t is the plate thickness). , the rewinding roller 3 is driven and controlled by a command signal from the control device S to set the length of rewinding the ribbon 1, and the length of the rewinding roller 3 is set, and the length is shifted by a predetermined pitch stepwise from the outermost circumferential side toward the inner circumferential side. Cut sequentially. In this example, a plurality of thin strips 1 (approximately 5 to 10 strips) are cut as one unit, and the core material 5 is cut to have the same dimensions to form one turn of the core laminates 8. After cutting one unit of the core laminate 8, it is taken out from the material storage trough 7, and as shown in FIG. Arrange them with 8 facing down. Thereafter, the ribbon 1 is cut, and the core laminates 8 of each winding layer are sequentially stacked and arranged on a positioning jig 9 at staggered positions. Then, a set of laminated blocks 10a is formed by laminating a plurality of layers (nine layers in this example) of iron core laminates 8 on the positioning jig 9. First laminated block 10
As shown in FIG. 4, this block 10a is placed on a workbench 11 by temporarily fixing it with a simple fixing means such as a clip to prevent it from being displaced from the positioning jig 9. At this time, on the outermost side of the laminated block 10a located at the outermost periphery of the wound core, a molded piece having the same width as this but with a length longer than the standard circumference by 2πt and thicker than the thin strip 1 is placed. A holding plate 12 (silicon steel strip, metal plate made of copper, etc.) is laid down. Next, on the first laminated block 10a,
The second laminated block 10b is mounted. This case is also similar to the case of forming the first laminated block 10a. That is, the thin strip 1 is sequentially cut into required dimensions by the cutting device A, and the cut iron core laminates 8 for one turn are stacked one by one on the intelligent determining jig 9 while shifting their positions stepwise in the same manner as described above. 2 laminated blocks 10b are formed. The second laminated block 10b thus formed is stacked on the first laminated block 10a on the workbench 11.
In this case, the intermediate layer of the first laminated block 10a,
That is, in this example, the longitudinal center of the fifth layer of iron core laminates 8 is aligned with the center of the intermediate layer of iron core laminates 8 of the second laminated block 10b. In this way, the thin strip 1 is cut to a predetermined size, one unit of core laminates 8 is sequentially provided, and the core laminates 8 are divided into units according to the required number and the ends of each core laminate 8 are shifted in a step-like manner. A set of laminated blocks 10a to 10d is formed. That is, the long laminated block 10a located on the outer peripheral side of the wound core is located at the bottom,
Short laminated block 10d located on the inner circumferential side
is located at the top and each laminated block 10a~
Stack 10d. Then, the laminated block 1
Among 0a to 10d, on the innermost laminated block 10d of the wound core is a molded holding plate 1 having the same dimensions.
Place 2a.

Next, as shown in FIG. Tighten and secure together. Next, each laminated block 10a~
10d is reversed 90 degrees from the state shown in FIG. 4, and placed on the table 15a of the molding apparatus 15 shown in FIG. 5 with the stacked end surfaces of the stacked blocks 10a to 10d facing upward. The forming device 15 is disposed at both ends of the laminated block 10a on the outermost periphery of the wound core, and moves along the guide grooves 16 formed in an eight-shape on the table 15a in the front-rear direction (fifth upper and lower positions) of the table 15a. a cylinder 1 rotatably supported at a base end connected to rollers 17, 17a that move in a direction) and that moves the rollers along a guide groove 16;
8, 18a and rollers 19, 20, 2 arranged between the cylinders 18, 18a to control the tension of the belt.
0a, the auxiliary cylinders 21a, 21a, the four guide rollers 22 disposed in front of the presser plate 13, and the roller 1.
7, 17a, 19, 20, 20a, 22, as shown in FIG.
It is composed of: When molding the laminated blocks 10a to 10d on the table 15a,
As shown in FIG. 5, a hemispherical core bar 24 whose diameter is slightly smaller than the inner diameter of the wound core is arranged on the front surface of the presser plate 13a (in the upper direction in FIG. 5) so as to surround the presser plate 13a. Also, inside the core bar 24, a stopper 25, which is removably attached to the table 15a, is brought into contact with the holding plate 13a. In this state, the cylinders 18 and 18a are driven to
7, 17a along the guide groove 16 on the table 15.
When the belt 23 is pushed toward the front side of the roller 1
7 and 17a are tensioned as they move, and both ends of each laminated block 10a to 10d are bent in directions facing each other. At this time, in order to maintain the tension of the belt 23 well, each of the main and auxiliary cylinders 21 and 21 is
a, 21a to drive rollers 19, 2, respectively.
0 and 20a are gradually moved in the direction of loosening the belt 23 to uniformly adjust the tension of the belt 23. Then, the rollers 17, 17a are connected to the guide groove 16.
When moving to near the tip of each laminated block 10
As shown in FIG. 6, a to 10d are bent into a substantially U-shape along the outer periphery of the core bar 24. Note that during bending, the laminated block groups 10a to 10d are supported by the stopper 25 and do not move on the table 15a. With the laminated blocks 10a to 10d held in a U-shape by the rollers 17 and 17a, the end of the inner molded holding plate 12a is wrapped along the core metal 24 as shown in FIG. Temporarily fasten with adhesive tape, etc. After temporarily fixing the inner molded retaining plate 12a, among the laminated blocks 10a to 10d bent in a U-shape, the core laminated plates 8 of the laminated block 10d located on the innermost circumferential side of the wound core are sequentially removed. As shown in FIG. 7, each laminated block 10a is stacked with the left and right ends alternately stacked on top of each other.
The ends of the core laminates 8 of ~10d are joined. At this time, since the core metal 24 is provided with a diameter slightly smaller than the inner diameter of the wound core, each laminated block 10a
The joint portion of the iron core laminate 8 at ~10d is the 11th
As shown in the figure, for example, one end a ₁ , a ₂ , a _{3 .} . . and the other end b ₁ , b ₂ , b ₃ .
are joined in a mutually polymerized state. As shown in FIG. 8, after the laminated blocks 10a to 10d are joined, a molded holding plate 12 placed outside the curved laminated block 10a is attached to the laminated block 1.
It is curved along the outer periphery of 0a and its ends are abutted,
A support plate 26 is brought into contact with this abutting portion, and this support plate 26 is welded to the molded holding plate 12 by spot welding, and the ends of the molded holding plate 12 are joined and fixed to form a wound core body 27. After this, roller 17,
17a releases the pressure on the laminated block groups 10a to 10d, returns the rollers 17 and 17a to their original positions as shown in FIG. , once remove the stopper 25. In this state, as shown in FIG. 9, the presser plate 1 inside the laminated block 10d
Insert the presser plate 13b into the position corresponding to 3a.
Subsequently, a flat wedge plate 28 is inserted between the press plates 13a and 13b using the insertion grooves a provided in the press plates 13a and 13b, and is press-fitted using a press (not shown). By press-fitting the wedge plate 28, the inner molded plate 12a is released from its temporary fixation and gradually deforms from a circular state to a rectangular shape together with the wound core body 27. In FIG. 7, each laminated block 10a to 1
As the rectangular shape progresses, the overlapping portions at the joints that occur when joining the ends of the core laminates 8 forming 0d are gradually expanded and joined in a normal joint state. That is, during the rectangular formation of the wound core body 27, the laminated block 1 adjacent to the wedge plate 28
Although the overlapping portions of the ends of the core laminates 8 of 0d and 10c can be spread and joined relatively well by effectively utilizing the force when the wedge plate 28 is press-fitted, Laminated block 10a,
10b, it is difficult to apply force when the wedge plate 28 is press-fitted. In this case, since there is a gap between the outer molded holding plate 12 and the outermost laminated block 10a, a light impact is applied from the outside of the molded holding plate 12, and the laminated block 10 is removed using the gap.
By loosening the overlapping portions of the ends of the core laminates 8 constituting a, the overlapping portions of the laminated blocks near the outer periphery of the wound core can be relatively well spread, and the ends of the core laminates 8 of the laminated blocks can be loosened. As shown in FIG. 12, the parts are joined in a normal joined state. When the press-fitting of the wedge plate 28 is completed, the wound core body 27 is formed into a substantially rectangular shape, as shown in FIG. By fixing the holding plate 13c and the tightening bolt 14, the yoke portion of the wound core is fixed by the other holding plate 13, 13a. Thereafter, as shown in FIG. 13, by lightly pressing the legs of the wound core from the outside to the inside with the forming plate 29, the wound core is maintained from the approximately rectangular state shown in FIG. 10 to the rectangular state. let In this state, an excitation coil 30 is wound around the leg of the wound core from the outside of the molded plate 29, and this is placed in an annealing furnace and annealed in a magnetic field to form an amorphous magnetic thin film that forms each laminated block 10a to 10d. The internal strain of the iron core laminate 8 made of a strip is removed. After annealing, excitation coil 30, forming plate 29, presser plate 13~
By removing 13c, manufacturing of the wound core 31 is completed.

In the present invention, after manufacturing the wound core 31, the molded holding plates 12, 12a are wound around the inside and outside thereof, so when the wound core 31 is lifted or transported after annealing, an external force is applied to the wound core 31 itself. It is possible to prevent deformation or peeling off of a part of the iron core laminate 8 even when the iron core laminate 8 is worn.

When assembling the core by inserting this wound core 31 into a coil (not shown), the formed holding plates 12, 1
Perform by removing 2a.

〔Effect of the invention〕

As explained above, the present invention can form a required number of laminated block groups by dividing and laminating a plurality of iron core laminates, which are prepared by cutting a plurality of amorphous magnetic thin strips into required lengths. This laminated block group is bent into a substantially circular shape by arranging thick metal molded holding plates on the innermost and outer sides thereof, and then, both ends of the laminated block group are overlapped with each other, and the above-mentioned inner A one-turn cut type wound core made of an amorphous magnetic ribbon is obtained by fixing an outer forming holding plate and forming a group of laminated blocks formed into a substantially circular shape into a rectangular shape. It has a similar effect.

(1) In the conventional method of winding an amorphous magnetic ribbon while cutting it to the required length, the cut iron core material may shift during winding, which may adversely affect the joints. Completely different from such cases, when the laminated block group is formed into a circular shape, the ends will overlap once, but by forming the wound core into a rectangular shape, the joints of the wound core will be uniformly regular. Since it can be joined in a joined state, there is no particular adverse effect on the core characteristics of the wound core.

(2) In addition, the rectangular shape of the wound core and the joining of the core can be successfully performed in one step, simplifying the manufacturing process of the wound core.

(3) Furthermore, since the wound core is manufactured through the process of stacking multiple core laminates cut to the required length and forming them from circular to rectangular, unlike conventional methods, amorphous material is removed during winding. There is no possibility that the magnetic ribbons will become uneven and the end faces of the winding layers of the wound core will be uneven, which will cause noise generation.Furthermore, the joints can be bonded well, which improves the core properties. It is possible to manufacture an excellent wound core.

(4) Furthermore, after manufacturing the wound core obtained by the present invention,
Molded retaining plates are attached to the inner and outer circumferential surfaces of the core while it is inserted into the coil, so that the core, which has become weak after annealing, may be partially deformed by external forces such as vibration during transportation. It also has the advantage of being able to protect it from being lost.

[Brief explanation of the drawing]

1 to 10 show an embodiment of the wound core manufacturing method of the present invention, in which FIG. 1 is a schematic diagram of a cutting device for cutting an amorphous magnetic ribbon, and FIG. An enlarged cross-sectional view taken along the - line in the figure, Fig. 3 is an explanatory diagram showing a state in which iron core laminates are stacked in a stepwise manner, each unit consisting of a plurality of cut amorphous magnetic ribbons, and Fig. 4. FIG. 5 is a schematic plan view of a forming apparatus for forming a group of laminated blocks of iron core laminates into a substantially circular shape, and FIGS. 6 to 10 is an explanatory diagram showing the sequence of operations for forming a stacked block group into a substantially circular shape and forming it into a rectangular shape;
Fig. 11 is an enlarged cross-sectional view of the joint before the forming process of the wound core is completed, Fig. 12 is an enlarged cross-sectional view of the joint after the forming process, and Fig. 13 is annealing of the wound iron core in a magnetic field. FIG. 14 is a front view of a wound core manufactured according to the present invention. 1...Amorphous magnetic ribbon, 8...Iron core laminate, 10
a to 10d... Laminated block, 12, 12a...
Molded holding plate, 27... wound core element, 31... wound iron core.

Claims (1)

[Claims] 1. A step of cutting one unit of iron core laminate, which is obtained by cutting a plurality of amorphous magnetic ribbons with the same dimensions, from the outermost periphery of the wound core toward the inner periphery, each unit having equal dimensions;
a step of dividing each of the cut iron core laminates into a plurality of units and sequentially stacking the iron core laminates of each division unit while shifting them in a stepwise manner to form a required number of laminated block groups; forming the laminated block group into a substantially U-shape by arranging molded holding plates thicker than the amorphous magnetic ribbon at the innermost and outermost positions, and forming the laminated block group into a substantially U-shape; a step of overlapping and joining both ends of the block group together with the inner molded retaining plate, and joining and fixing the outermost molded retaining plate of the laminated block group with the regular dimensions to form a substantially circular wound core body; A winding comprising the steps of forming the wound core element into a rectangle to eliminate overlapping portions at both ends of the laminated block group and abutting them normally, and annealing the rectangular wound core in a magnetic field. Iron core manufacturing method.