JPH0568084B2 - - Google Patents

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a method for assembling a double-insulated transformer by inserting and holding a primary coil and a secondary coil into a double-insulated bobbin case. The present invention relates to a method for assembling a double insulation structure transformer, which can improve workability and automate the assembly of the transformer.

[Conventional technology]

Generally, a transformer is manufactured by completing the necessary steps on the spot, such as winding wire around a bobbin to form a coil, inserting the core into the center hole of the coil, and then pulling out the lead wires. It was then assembled and provided to users as a finished product.

A conventional double insulation structure transformer consists of an E-type core block made up of a large number of laminated and fixed E-type cores, a primary coil and a secondary coil inserted into a double-insulated bobbin case, and an I-type core. It was combined with an I-shaped core block made by laminating and fixing a large number of. Here, in the bobbin case of the conventional double insulation structure transformer, as shown in FIGS. 6a to 6c, the bobbin 2 of the primary coil 1 (see FIG. 7) is inserted and the first fitting part 3 is inserted. and a second fitting part 6 into which the bobbin 5 of the secondary coil 4 (see FIG. 8) is inserted, and both 3 and 6 are formed adjacent to each other with an insulating partition 7 between them, In addition, on both sides of the first fitting part 3, there is a creepage distance between the cores inserted into the center holes 8, 8 of the primary coil 1 and the secondary coil 4 and the winding 9 of the primary coil 1. It was comprised of insulating collars 10, 10 to ensure that. And the bobbin case 11 having such a structure
On the other hand, as shown in FIG.
The notched end 1 of the insulating collar 10, 10
2, 12 (see Figure 6a) from the primary coil 1.
The bobbin 2 of the secondary coil 4 is inserted in the direction of the arrow A, and the bobbin 5 of the secondary coil 4 is inserted into the second fitting part 6 in the direction of the arrow B, thereby connecting the primary coil 1 and the secondary coil 4. It was combined with a heavy insulation structure.

[Problem to be solved by the invention]

However, when assembling a double insulation structure transformer using the bobbin case 11 as described above,
To combine the primary coil 1 and the secondary coil 4 into a double insulation structure, as shown in FIG. Insertion direction (arrow B direction)
Since the two coils are different from each other and their axes intersect at a substantially right angle, it is necessary to confirm the direction of insertion and to distinguish the direction of insertion for each coil 1 and 4. Therefore, bobbin case 1
It was difficult to insert the respective bobbins 2 and 5 into the bobbin 1, resulting in a decrease in work efficiency. Furthermore, for this reason, assembly of the transformer using a mechanical device requires a complex mechanism with multiple joints, and it has been difficult to automate the assembly of the double insulation structure transformer.

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for assembling a double insulation structure transformer, which can solve these problems, improve workability during assembly, and automate the assembly of the transformer.

[Means to solve the problem]

In order to achieve the above object, the method for assembling a transformer with double insulation structure according to the present invention includes an E-type core block formed by laminating and fixing a large number of E-type cores, and a primary core block which is assembled by inserting it into a double-insulation type bobbin case. In a method for assembling a transformer with a double insulation structure by combining a coil and a secondary coil with an I-type core block formed by laminating and fixing a large number of I-type cores, the E-type core block is placed in the mounting position with its legs facing upward. One of the above two coils is fitted into the foot of this E-shaped core block from above, and a primary coil and a secondary coil are fitted from above onto this one coil on the same axis but opposite to each other. A double-insulated bobbin case formed to cover the entire circumference of each winding section is fitted, and the other coil is inserted from above into this bobbin case. The I-shaped core block is fitted into the leg of the E-shaped core block, and the I-shaped core block is fixed to the tip of the E-shaped core block from above, so that it can be assembled by sequential stacking operations from a fixed direction. .

[Effect]

The method for assembling the double insulation structure transformer constructed in this way involves separately assembling the E-type core block, primary coil, secondary coil, bobbin case, and I-type core block as each component of the transformer. The product is completed by manufacturing each component and assembling each component in sequence from a fixed direction at the location where the transformer is actually installed in the final stage.

〔Example〕

Embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

FIG. 1 is an explanatory diagram showing a method of assembling a double insulation structure transformer according to the present invention. The double insulation structure transformer according to the method of the present invention is one that requires an insulation structure according to, for example, the IEC standard (an international safety standard stipulating safety mainly to prevent electric shock), and has an E-type core block 13, It is constructed by combining a primary coil 1, a bobbin case 14, a secondary coil 4, and an I-shaped core block 15.

In order to assemble this double insulation structure transformer, each component of the transformer is first manufactured separately. That is, the E-shaped core block 13 is formed into a block shape by laminating a large number of individual E-shaped cores and welding or caulking them. The primary coil 1 is formed by winding a winding 9 around a bobbin 2 having a center hole 8.
Further, the secondary coil 4 is formed by winding a winding 9 around a bobbin 5 having a center hole 8. moreover,
The I-shaped core block 15 is formed into a block shape by laminating a large number of individual I-shaped cores and welding or caulking them together.

Here, the bobbin case 14 is used to insert and hold the primary coil bobbin and secondary coil bobbin in a double-structure transformer that is required to have an insulating structure according to the IEC standard, and as shown in FIGS. 2 a to c, First fitting part 16, second fitting part 17, and insulating collar 1
8. The first fitting portion 16 is connected to the bobbin 2 of the primary coil 1 similar to the conventional one shown in FIG.
is inserted and held, and is formed into a substantially box-like shape from an appropriate insulating material. Further, the second fitting portion 17 is connected to the bobbin 5 of the secondary coil 4 similar to the conventional one shown in FIG.
It is formed of a suitable insulating material into a substantially box shape, and is formed adjacent to the first fitting part 16 with an insulating partition wall 7 between the two and the first fitting part 16. Note that, as shown in FIGS. 2a and 2c, the insulating partition wall 7 has a hole 19 bored in its center into which a core (iron core of a transformer) is inserted. Further, the insulating collar 18 secures a creepage distance between the cores (not shown) inserted into the center holes 8 and 8 of the primary coil 1 and the secondary coil 4 and the winding 9 of the primary coil 1. It is made of a suitable insulating material and is provided on both sides of the first fitting part 16. The first fitting part 16 and the second fitting part 17 are, as shown in FIGS. 2a and 2c, respectively, the outer peripheral part of the winding 9 of the primary coil 1 shown in FIG. Peripheral wall members 20a and 20b are formed around the entire circumference of the winding 9 of the secondary coil 4 shown in the figure. Further, the insulating collars 18, 18 are in a state where they can be bent inward at the end faces of the peripheral wall member 20a formed on both sides of the first fitting part 16, as shown in FIGS. 2a and 2b. It has been extended with.

As shown in FIG. 3, in the bobbin case 14 configured in this way, the first fitting part 16 and the second fitting part 17 are arranged on both sides of the opening surrounded by the peripheral wall members 20a and 20b. The insulating flanges 18, 18, which are oriented in the opposite direction to the first fitting part 16 and extend to both sides of the first fitting part 16, are arranged, for example, on the left side with respect to the first fitting part 16 in an upright state. Then insert the bobbin 2 of the primary coil 1 shown in FIG. 7 in the direction of arrow D, and insert the secondary coil shown in FIG. No. 4 bobbin 5 can be inserted in the direction of arrow E. Furthermore, as shown in FIG.
By bending the insulating flanges 18, 18 inwardly with each other in the inserted state, the insulating flanges 18, 18 are bent at right angles and overlapped on the outer surface of the bobbin 2. By using such a bobbin case 14, the primary coil 1 and the secondary coil 4 are combined into a double insulation structure.

In order to assemble the transformer with each of the component parts prepared in this way, first, as shown in FIG. , 13b, 13c facing upward. Next, one of the primary coil 1 and the secondary coil 4, for example, the secondary coil 4, is fitted into the central leg portion 13b of the E-shaped core block 13 from above. At this time, the center hole 8 of the bobbin 5 of the secondary coil 4 is
3b, and the winding 9 part is connected to the left and right foot parts 13.
It fits into the valley between a, 13c and the center foot 13b. Next, the bobbin case 14 is fitted onto the secondary coil 4 from above. This is the same state as inserting the secondary coil 4 into the second fitting portion 17 of the bobbin case 14 in the direction of arrow E in FIG. 3. Next, the other coil, for example, the primary coil 1, is inserted into the bobbin case 14 from above and fitted into the central foot 13b of the E-shaped core block 13. This is the same state as inserting the primary coil 1 into the first fitting portion 16 of the bobbin case 14 in the direction of arrow D in FIG. 3. At this time, the center hole 8 of the bobbin 2 of the primary coil 1 fits into the center leg 13b, and the winding 9 is connected to the left and right legs 13a, 13c and the center foot 13b. Fits into the valley between. In this state, the insulating collars 18, 18 extending on the edge of the bobbin case 14 are bent inwardly, and the bobbin 2 of the inserted primary coil 1 is folded inwards as shown in FIG. The insulating ribs 18, 18 are bent at right angles and overlapped on the outer surface. Finally, the I-shaped core block 15 is placed on the tips of the legs 13a to 13c of the E-shaped core block 13 from above the primary coil 1 and fixed by welding or the like. Thereby, as shown in FIG. 5, the double insulation structure transformer 22 is assembled and completed, for example, at the mounting position on the printed circuit board 21.

In addition, in FIGS. 1 and 5, the double insulation structure transformer 2 is mounted at the mounting position on the printed circuit board 21.
2 is shown as being assembled, but the present invention is not limited thereto, and may be assembled at any location where the transformer can be attached, such as a predetermined location on the chassis.

〔Effect of the invention〕

Since the present invention is configured as described above, E as each component of the double insulation structure transformer 22 is
The core block 13, the primary coil 1, the secondary coil 4, the bobbin case 14, and the I-type core block 15 are manufactured separately, and in the final step, each component is installed at the position where the transformer is actually installed. It can be assembled by sequential stacking operations from a fixed direction. Therefore, it is only necessary to sequentially fit or insert all the components from a certain direction, and the workability when assembling the transformer can be greatly improved. Also, from this fact, even though the transformer is assembled by mechanical equipment,
All that is required is a work arm that can only move horizontally and vertically, and the assembly of the double insulation structure transformer 22 can be automated with a simple mechanism. Furthermore, all conventional transformers were provided to the user as a finished product after assembly, but according to the present invention, the assembly operation is extremely simple, so the user can assemble the components at the location where the transformer is mounted. Each part can be assembled and installed as is. Therefore, manufacturers can provide each component of a transformer individually, and users can assemble and mount the transformer in the same way they mount components such as resistors, capacitors, and ICs when assembling various devices. .

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram showing a method of assembling a double insulation structure transformer according to the present invention, and FIG. 2 is a drawing showing the structure of a bobbin case according to the present invention, in which a is a left side view, b is a front view, and c is a diagram. A right side view, FIG. 3 is a perspective view showing the entire bobbin case, FIG. 4 is a perspective view showing a state in which a primary coil and a secondary coil are combined into a double insulation structure using the bobbin case. 5 is a perspective view showing the entire double insulation structure transformer assembled by the method of the present invention;
Figures a to c are explanatory diagrams showing a conventional bobbin case, Figure 7 is a perspective view showing a primary coil, Figure 8 is a perspective view showing a secondary coil, and Figure 9 shows how to coil a primary coil using a conventional bobbin case. FIG. 3 is a perspective view showing a state in which the and the secondary coil are combined into a double insulation structure. 1... Primary coil, 2... Primary coil bobbin, 4... Secondary coil, 5... Secondary coil bobbin, 8... Center hole, 9... Winding wire, 13... E-type core block, 13a-13c...foot part, 14...
...Bobbin case, 15...I-type core block, 2
1...Printed circuit board, 22...Double insulation structure transformer.

Claims (1)

[Claims] 1. An E-type core block formed by laminating and fixing a large number of E-type cores, a primary coil and a secondary coil inserted and combined into a double-insulated bobbin case, and an I
In the method for assembling a transformer with a double insulation structure, which involves combining an I-shaped core block made of a large number of laminated and fixed cores, an E-shaped core block is set in the mounting position with its feet facing upward, and the One of the above-mentioned two coils is fitted into the foot part from above, and a primary coil and a secondary coil are inserted into the one coil from above from opposite directions on the same axis, and the respective windings are inserted. A double-insulated bobbin case formed to cover the entire circumference of the wire section is fitted, and the other coil is inserted from above into the bobbin case, and the foot section of the E-shaped core block is fitted. A method for assembling a transformer with a double insulation structure, characterized in that the I-shaped core block is fitted onto the legs of the E-shaped core block from above, and the transformer is assembled by sequential stacking operations from a fixed direction.