JPH07130551A - Transformer and its manufacture, and resistance welding set - Google Patents

Abstract

PURPOSE:To improve the efficiency of utilizing the magnetic flux by decreasing leakage of magnetic flux of a split type core, to unnecessitate the pressure- welding and fixing tool of a core split piece, to simplify the assembling work of a transformer, and to obtain a lightweight and highly efficiency transformer at a high yield. CONSTITUTION:The core 100 comprises a core main body 10 which has coil housing spaces 10a and 10b therein, and in which a part of the magnetic path is opened, and yoke core members 20a and 20b which can be fitted into magnetic path open parts 10a1 and 10b1 and constitute a closed magnetic path together with the core main body 10. Coil assembled bodies 30a to 30c are installed in the coil housing spaces 10a and 10b of the core main body 10, and the yoke core materials 20a and 20b are fixed to the core main body 10 by welding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a transformer, a method of manufacturing the same, and a resistance welding apparatus, and more particularly, the size and weight of the transformer are improved, the efficiency is improved, the manufacturing work is simplified, and the welding capacity of the resistance welding apparatus is further improved. Specifically, for example, it is useful as a high-efficiency power transformer with a large power factor and a sharp rise characteristic of current, which has a large capacitance between the primary and secondary coils. In particular, the present invention relates to a spot welding of aluminum material through an adhesive, general arc welding, and a transformer which is excellent as a power transformer for precision motors, vibrators, photothermal equipment, and the like.

[0002]

2. Description of the Related Art A transformer is composed of a common magnetic circuit and a plurality of coils interlinking with the common magnetic circuit. An AC input is applied to a predetermined coil, and a voltage and a current are transformed by an electromagnetic induction effect to transform the predetermined coil from the predetermined coil. It is a device that outputs AC power. Specifically, the common magnetic circuit is an iron core.
When a secondary coil and a secondary coil are mounted and an AC voltage is applied to the primary coil and a load is connected to the secondary coil, a voltage proportional to the number of turns of the primary and secondary coils is applied to the load. To be done.

FIGS. 24 (a) and 24 (b) show an example of the structure of a conventional transformer. Here, a transformer having E and E-shaped iron cores which can be separated from each other is taken as an example. In the figure, 610
Is a center core iron core of a type in which a coil is attached to the central leg 610a, and is composed of a divisible E-shaped upper iron core portion 601 and an E-shaped lower iron core portion 602. A coil assembly 640 including a combination of a primary coil and a secondary coil is attached. Each iron core 60
1, 602 has a structure in which E-shaped thin iron plates 601a and 602a are laminated, and the upper and lower E-shaped iron core portions 6 are formed.
01 and 602 are press-fitting fixtures 6 as shown in FIG. 24 (b).
It is assembled and held by 20.

That is, here, as the pressure contact fixing member 620, the upper and lower angle members 621a to 624a,
A pair of rectangular holding frames 620a and 620b, which are formed by welding 621b to 624b together by welding, are used. The upper and lower E-shaped iron core portions 601 are formed by these holding frames.
Hold 602 from both sides in the stacking direction of the thin iron plates,
Bolts 631a are inserted through bolt insertion holes 625a, 625b formed at the four corners of each holding frame 620a, 620b, and nuts 631b are screwed into the bolts 631a, and the upper and lower E-shaped iron core portions 601 and 602 are fixed by pressure. .

FIG. 25 shows another example of the configuration of a conventional transformer. In this example, three small inner iron cores 261 formed by abutting a pair of small cut cores 261a are arranged in the lateral direction, and a larger cut core 260a is provided. Are assembled to wrap the three inner iron cores 261 to form an outer iron core 260, which constitutes an iron core of the transformer. Here, a band member (not shown) is wound around each iron core to hold it in pressure contact, and the abutting surface of each cut core is mirror-finished.

[0006]

Since the conventional transformer is constructed as described above, the one shown in FIG.
In addition to the main body of the iron core, the transformer requires a pressure welding fixture that presses and holds the iron core, which makes the entire transformer bulky. Further, in manufacturing the transformer, the press-contact fixing tool 620 is attached to the iron core, that is, the pair of holding frames 620a, 62.
0b sandwiches the upper and lower iron core parts 601 and 602, and further, a bolt is inserted into the holding frame, and a nut is screwed into the holding frame to tighten the nut, which makes it difficult to manufacture the conventional transformer. It was a thing. Also in FIG.
In the case shown in (1), mirror finishing of the abutting surfaces of the cut cores and tightening work of the cut cores with a band member are required, and the conventional transformer manufacturing is time-consuming.

[0007] A transformer is indispensable especially for a power supply device of various electric devices related to high electric current. For example, in a resistance welding device such as spot welding, a pole transformer of a power company or a high voltage power receiving transformer for private use is used. Through spot welding, a dedicated transformer was installed to perform spot welding work. In spot welding, the output obtained on the secondary side is different from the primary input that is input on the primary side of the transformer. The average value was about 40%, and the power conversion efficiency was not favorable.

This is because such a resistance welding machine usually uses a single-phase AC power, has a large input apparent power when energized, and has a low power factor load, which improves the power factor. Various measures are considered. One of them is a condenser discharge type welding machine. This is to rectify an alternating current power source with a rectifier into a direct current, charge a capacitor with the direct current,
The charged electric charge is discharged to the primary side of the welding transformer and a large current instantaneously generated on the secondary side is used, which is suitable for a place with a small power source capacity.

However, such a capacitor discharge type welding machine is also not suitable for a welding current requiring a relatively long time (about 0.5 seconds) such as welding of a thick plate, and the welding surface is free from oil and dust. Spot welding and the like have been difficult for a member to be welded that is dirty or has a rough surface. Further, there are inconveniences that it is not possible to perform spot welding by stacking several aluminum plates or to perform spot welding with a sealer agent or the like for preventing water from entering the welding surface of the member to be welded. Further, the welded portion is fragile, and when the spot-welded member is used in a portion of a mechanical device where vibration is severe, there is a problem that the member comes off. For this reason, spot welding with good workability cannot be used for welding of members that require particularly high reliability, such as welding of the wing portion of an airplane, and it is difficult to use spot welding, that is, FIG. a)
And an aluminum plate 801, which is joined as shown in FIG.
The rivet 804 was inserted into the rivet insertion hole 803 of 802, the head portion 804a of the rivet was deformed, and the two aluminum plates were joined. However, in this case, there is a problem that a crack 810 is generated from the hole 803 for mounting the tack 804 (FIG. 26 (c)) and if this part is damaged, a serious accident may occur.

The present invention has been made in view of the above-mentioned conventional problems, and an object thereof is to obtain a transformer having a compact structure which can improve the power conversion efficiency by eliminating the leakage of magnetic flux and is small in size and lightweight. .

Another object of the present invention is to provide a method of manufacturing a transformer, which enables the split type iron cores to be easily joined to each other, whereby the transformer can be manufactured with good workability.

Further, according to the present invention, the reactive current can be reduced and the welding current contributing to the heating and melting of the welded portion can be increased, whereby when welding a member to be welded having a slight insulating coating on the surface of the welded portion, Alternatively, even when several members to be welded are overlapped and welded, it is an object to obtain a resistance welding apparatus capable of performing strong welding resistant to vibration by sufficiently heating and melting the welded portion. To do.

[0013]

A transformer according to the present invention is formed by laminating a plurality of first thin iron plates having the same shape, has a coil accommodating space therein, and has a magnetic path partially open. The main body and the iron core body are mounted in the coil accommodation space,
A ring-shaped coil assembly formed by combining a secondary coil and a secondary coil, and a plurality of second thin iron plates having the same shape are laminated, fitted into the magnetic path opening portion of the iron core body, and fixed by welding. And a yoke core material that forms a closed magnetic circuit with the iron core body.

In the method for manufacturing a transformer according to the present invention, an iron core body having a coil housing space therein and a part of a magnetic path opened is assembled by laminating a plurality of first thin iron plates of the same shape, and A yoke core material that is fitted into the magnetic path opening portion of the iron core body to form a closed magnetic path with the iron core body.
A plurality of second thin iron plates having the same shape are stacked and assembled, and a ring-shaped coil assembly formed by combining a primary coil and a secondary coil is mounted in the coil housing space of the iron core body, and then the iron core is mounted. The yoke core material is fitted into the magnetic path opening portion of the main body, and the surfaces of these joint portions are resistance-welded.

According to the present invention, in the transformer and the manufacturing method thereof, as the first and second thin iron plates, each of the divided pieces obtained by cutting one thin iron plate material having a predetermined shape at a predetermined site and dividing the thin iron plate material is cut. First and second thin iron plates obtained by dividing a plurality of first thin iron plates constituting the iron core body and a plurality of second thin iron plates constituting the yoke core material from the same thin iron plate material They are laminated in a predetermined order so that they face each other.

According to the present invention, in the transformer and the method of manufacturing the same, on the front and back side first thin iron plates of the laminated body of the first thin iron plates, the portion thicker than the first thin iron plate and the magnetic path open portion A first auxiliary iron plate having a different opening shape is further stacked and attached, and the magnetic path of the first auxiliary iron plate is thicker than the second thin iron plate on the front and back side second thin iron plates of the laminated body of the second thin iron plates. A second auxiliary iron plate having a shape that can be fitted into the open opening is further stacked and attached.

According to the present invention, in the above transformer, the iron core main body is arranged on both sides of an E-type iron core portion formed by laminating E-type thin iron plates and a central leg of the E-type iron core portion. , The U-shaped iron cores formed by stacking U-shaped thin iron plates are combined, and the upper and lower internal spaces of the E-shaped iron cores and the interiors of the upper and lower U-shaped iron cores are combined. A space is defined as the coil accommodating space, and a yoke core material forming a closed magnetic path is fitted into each of the magnetic path open portions of the E-shaped iron core portion and the U-shaped iron core portion by welding and fixed. It was done.

According to the present invention, in the method for manufacturing a transformer, as the second thin iron plate constituting the yoke core material, when the yoke core material is attached to the magnetic path opening portion of the iron core body, the iron core A thin iron plate corner is chamfered so that a groove is formed on the outer surface of the joint between the main body and the yoke core material.The iron core body and the yoke core material are A core material is mounted, a welding metal rod is arranged in a groove on the outer surface of the joint portion, and a positive electrode side prismatic electrode having the same length as the welding metal rod is pressure-welded to the welding metal rod. A negative electrode welding electrode of the same shape is pressed onto the yoke core material in the vicinity of the joint, and in this state, a welding current is applied to both of the welding electrodes to spot weld the joint.

According to the present invention, in the above-mentioned method for manufacturing a transformer, a roller type movable electrode is used in place of the positive electrode side prismatic electrode, and an electrode having a predetermined shape is used in place of the negative electrode side prismatic electrode. The movable electrode of the mold is rotationally moved on the welding metal rod and a welding voltage is applied to seam weld the joint.

In the resistance welding apparatus according to the present invention, the transformer having the above structure is used as the transformer of the power supply device, and the secondary coil of the coil assembly is transformed by the capacitance between the primary coil and the secondary coil. In order to cancel out the inductive reactance component of the above, it is configured by stacking multiple copper plates that form a peripheral circuit around the iron core leg, and supplies the welding electrode with a welding current that sharply rises at the same time when the output voltage is generated. It is the one.

In the resistance welding apparatus according to the present invention, as the welding electrodes, a pair of adjacent upper and lower welding electrodes are provided, and the transformer is provided for each of the welding electrodes. , The upper and lower welding electrodes of each set and the secondary coil of the transformer corresponding to these, at the initial stage of welding, between the upper welding electrodes adjacent to each other and between the lower welding electrodes, the upper welded member, The wires are connected so that an electric current can flow through the lower member to be welded.

According to the present invention, in the above resistance welding apparatus, a phase control circuit is provided on the input side of the transformer for controlling the ignition of the supply of three-phase alternating current for each phase, and the transformer has a single-phase iron core. Three primary coils are wound on the primary side, a single-phase coil is wound on the secondary side, and the three primary coils are respectively connected to respective phases of a three-phase AC power source via the phase control circuit,
The phase control circuit controls the phase of each phase of the three-phase AC power source to output a single-phase AC to the secondary coil.

[0023]

According to the present invention, the iron core of the transformer can be fitted into the iron core body having the coil housing space inside and the magnetic path partially open, and the magnetic path open portion of the iron core body. There is a yoke core material that constitutes a closed magnetic circuit together with the iron core body, the coil assembly is mounted in the coil accommodating space of the iron core body, and the yoke core material is welded to the iron core body. Since they are fixed to each other, leakage of magnetic flux at the joint between the iron core body and the yoke core material can be reduced, and the power conversion efficiency of the transformer can be significantly improved. In addition, since both iron core materials are fixed by welding, a pressure welding fixture for both iron core materials is not required,
The whole transformer can be made compact and the work of assembling the transformer can be simplified.

Further, in the present invention, the iron core body and the yoke core material are constructed by laminating the first and second thin iron plates, respectively, and the first and second thin iron plates have a predetermined shape, respectively. A plurality of first thin iron plates forming the iron plate main body and a plurality of second thin iron plate members forming the yoke core material are formed by using each divided piece formed by cutting one thin iron plate material at a predetermined portion and dividing it.
And a thin iron plate of No. 1 are laminated in a predetermined order so that the first and second thin iron plates divided from the same thin iron plate material face each other when the yoke core material is attached to the magnetic path opening portion of the iron core body. Therefore, it is possible to substantially eliminate the gap at the joint between the iron core body and the yoke core material, and further reduce the leakage of magnetic flux.

Further, according to the present invention, a first auxiliary iron plate which is thicker than the first thin iron plate and which has a different opening shape at the magnetic path opening portion is superposed on the first thin iron plate on the front surface and the back surface of the iron core body. Installed on the front and back of the yoke core material
Since the second auxiliary iron plate, which is thicker than the second thin iron plate and has a shape that can be fitted into the magnetic path opening of the first auxiliary iron plate, is mounted on the thin iron plate, the iron core body and the yoke core material are reinforced. It is possible to align the yoke core material with the iron core body by the auxiliary iron plate inner surface and the thin iron plate outer surface,
Positioning of both iron core materials becomes easy.

Further, in the present invention, the above-mentioned iron plate body is arranged on both side surfaces of an E-type iron core portion formed by laminating E-type thin iron plates and a central leg of the E-type iron core portion, And a U-shaped iron core portion formed by laminating thin iron plates of a mold, and the upper and lower spaces of the E-shaped iron core portion and the internal spaces of the upper and lower U-shaped iron core portions are formed as described above. Since the coil accommodation space is used, and the magnetic core opening portions of the E-shaped iron core portion and the U-shaped iron core portion are fitted and welded and fixed with the yoke core material forming the closed magnetic circuit with the respective iron core portions, Since the four sides of the coil will be surrounded by the iron core, the leakage of the magnetic flux generated in the coil will be greatly reduced, the magnetic path will be shortened and the magnetic resistance will be reduced, and the power conversion efficiency of the transformer will be greatly improved. You can In addition, since the iron core body and the yoke core material are joined by welding, there is no need for a device to hold these iron core members in pressure contact, and the transformer can be made compact. It is possible to eliminate the troublesome work of sandwiching the holding frame and further tightening the holding frame with bolts and nuts to fix the iron core. As a result, the transformer can be manufactured with good workability.

In the present invention, as the second thin iron plate constituting the yoke core material, when the yoke core material is attached to the magnetic path opening portion of the iron core body, the iron core body and the yoke core material are provided. A groove is formed on the outer surface of the joining part of, using a thin iron plate corner portion chamfered, the iron core body and the yoke core material, the yoke core material is attached to the iron core body, A metal rod for welding is placed in the groove on the outer surface of the joint and spot welding or seam welding is performed on this portion, so welding of the iron core body and yoke core material can be performed easily and reliably. it can.

Further, in the present invention, the transformer having the above structure is used as the transformer of the power supply device of the resistance welding apparatus, and the secondary coil of the coil assembly is transformed by the capacitance between the primary coil and the secondary coil. In order to cancel out the inductive reactance component of the reactor, it is constructed by stacking multiple copper plates that form a peripheral circuit around the iron core leg, and a welding current that rises sharply at the same time as the output voltage is generated is supplied to the welding electrode. So, at the same time as the output voltage of the transformer is generated,
A large current with a steep rise flows through the work piece sandwiched between the welding electrodes, which may cause some insulation film on the surface of the work piece, or some of the work pieces to overlap. Even if there is, it is possible to sufficiently heat and melt the welded portion to perform strong welding resistant to vibration.

Further, in the present invention, as the welding electrodes, two pairs of upper and lower welding electrodes are arranged close to each other, and the above-mentioned transformers are provided for the respective welding electrodes of each group, and the welding electrodes of each adjacent group are arranged. Insulation is made between the welded members by connecting the upper welded electrodes and the lower welded electrodes so that current can flow through the upper welded member and the lower welded member. Even if a conductive coating is present, the insulating coating is melted or carbonized by the heating effect of the current flowing between the adjacent welding electrodes to establish a state in which the upper and lower welding electrodes can be electrically connected, and resistance welding is thereby performed. You can

Further, in the present invention, the iron core of the transformer of the resistance welding apparatus is a single-phase iron core, and the primary side of the single-phase iron core has a three-phase primary coil and the secondary side has a single-phase primary coil. Of 2
The secondary coil is wound around and the phase control circuit controls the phase of the three-phase alternating current to supply it to the three-phase primary coil and outputs the single-phase alternating current to the secondary coil. By controlling the phase of each phase, it is possible to obtain a composite waveform equivalent to a single-phase output of a sawtooth wave at triple frequency, and thereby a single-phase output composed of the composite waveform is provided on the secondary side of the transformer. Can be generated. Further, by controlling the phase, the obtained output waveform can be made a waveform suitable for spot welding.

[0031]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is an explanatory view of a transformer according to an embodiment of the present invention,
FIG. 2 is a view showing the structure of a thin iron plate that constitutes the iron core. In the figure, 10 is a three-phase inner iron type iron core 1 of the transformer 1.
00 is an E-type iron core main body formed by laminating a plurality of E-shaped first thin iron plates 11, and an opening is provided between the central iron core leg 10c and the left and right iron core legs 10e and 10d. , Through the openings 10a ₁ and 10b ₁ into the coil housing spaces 10a and 10b inside the iron core body 10 and the coil assemblies 30a to 30b.
c can be attached. The opening between the central iron core leg 10c and the left and right iron core legs 10e, 10d,
That is, the magnetic path open portions 10a ₁ and 10b _{1 of the} iron core body 10
Yoke core materials 20a and 20b formed by laminating a plurality of inverted trapezoidal second thin iron plates 21 are fitted in and fixed to the iron core body 10 by welding. I am configuring. Here, W is a welded portion, and 51 is a bolt or nut for fixing the laminated first and second thin iron plates 11.

Here, the first thin iron plate 1 of the iron core body 10 is
1 and the second thin iron plate 21 of the yoke core members 20a, 20b, the rectangular thin iron plate member 41 having rectangular opening portions 41a, 41b on the left and right as shown in FIG. One E-shaped divided piece obtained by cutting at a predetermined portion and two inverted trapezoidal divided pieces, and here, a plurality of first thin iron plates 11 constituting the iron core body, and the yoke. Core material 20
The plurality of second thin iron plates constituting a and 20b are laminated in a predetermined order so that those obtained from the same thin iron plate material 41 face each other. Further, the upper side corner portion 211 of the second thin iron plate 21 is chamfered.

The coil assemblies 30a to 30c are
Each of them is a combination of a primary coil and a secondary coil. As shown in FIG.
The structure is formed by sequentially stacking the sheet by reversing the direction of the sheet through the sheet 2. Here, in the coil copper plate 31, as shown in the figure, a rectangular copper plate is hollowed out to form a central hole portion 31a, and subsequently both end pieces 31c and 31 are formed.
A copper plate formed so as to have a slit portion 31b between it and d is used, and the insulating plate 32 has a central hole portion having the same outer shape as the copper plate 31 and the same shape as the central hole portion 31a. The one having 32a is used. 31e
Is a connection hole. In this case, the copper plates having the connection holes 31e on the lower left side of the paper are connected in parallel to form the secondary coil, and the copper plates having the connection holes 31e on the upper right side of the paper are connected in series to form the primary coil. Are configured.

Next, a method of manufacturing the above transformer will be described. First, a bolt insertion hole 40a is formed in the peripheral portion of a rectangular thin iron plate material 40 of a predetermined size (FIG. 2 (a)), and two central portions are hollowed out to form two opening portions 41a and 41b.
A thin iron plate material 41 is formed (FIG. 2 (b)). Next, the upper side portions of the left and right openings 41a and 41b of the thin iron plate material 41 are cut at predetermined portions to form one E-shaped first thin iron plate 11 and two inverted trapezoidal second thin iron plates 21. Yes (Fig. 2
(b), (c)). Then, the upper side corner portion 211 of the second thin iron plate 21 is chamfered. (Fig. 2 (d)).

Next, a predetermined number of the first thin iron plates 11 are laminated, the fixing bolts 51 are inserted into the respective bolt insertion holes 40a, and the nuts 52 are screwed into the tips to assemble the E-type iron core body 10. Next, similarly, a plurality of the second thin iron plates 21 are laminated and bolts, nuts 51 and 52 are mounted in the bolt insertion holes 40a to assemble the yoke core material 20. Here, two yoke core materials 20a and 20b are assembled (FIG. 3).

On the other hand, the coil copper plate 31 is replaced with the insulating plate 3 by
2. The copper plate having the connection holes 31e on the lower left side of the paper is connected in parallel to form a secondary coil, and the copper plate having the connection holes 31e on the upper right side of the paper is stacked. Are connected in series to form a coil assembly 30 as a primary coil (FIG. 4). Here, three coil assemblies 30a to 30c are formed (FIG. 5).

Subsequently, each coil assembly 30 is attached to each of the left and right iron core legs 10c, 10e and 10d in the center of the iron core body 10.
c, 30b, 30a are attached (Fig. 5), and the iron core body 1 is
0 of the magnetic path opening 10a of the two positions _1, 10b _1, each yoke core 20a, mounting fitting to 20b (FIGS. 6 (a)
). And the chamfered portion 2 of each of the yoke core materials 20a, 20b
The welding iron wire 70 is arranged in each of the V-grooves 212 formed by 11 and the inclined surface of the tip of each iron core leg (Fig. 6 (b)).
), Resistance welding this part.

That is, as shown in FIG. 7, the welding device 260 is hung from the tip of the balancer arm 240 via the spring member 241 and placed above the assembled iron core up to the state shown in FIG. 6 (b). At the bottom of this welding device 260,
Positive and negative side welding electrodes 270a and 270b are arranged by being biased downward by biasing springs 271a and 271b, respectively. The positive side welding electrodes 270a are connected to the welding iron wire 70.
The welding device 260 is positioned above, the welding device 260 is moved downward, and a predetermined pressure is applied to the welding iron wire 70 by the welding electrode 270a. Then, in this state, the transformer section 2 of the welding device
When an AC power supply is applied to the primary coil 261 of 60, a welding current is applied from the secondary coil 262 to the positive and negative welding electrodes 270a and 270b, and the welding iron wire 70 and the iron core material of the peripheral portion thereof are removed. After melting, the iron core body 10 and the yoke core material 20 are welded. Such welding work is performed on the joint portion between the iron core body 10 and each yoke core material 20a, 20b to complete the iron core of the transformer.

As described above, in the present embodiment, the iron core 100 of the transformer is provided with the coil housing spaces 10a and 10b therein, and the iron core body 10 with a part of the magnetic path open, and the iron core body 10 of the iron core body. In the coil accommodating spaces 10a, 10b of the iron core body 10, the yoke core material 20 is capable of being fitted into the magnetic path opening portions 10a ₁ , 10b ₁ and constitutes a closed magnetic path together with the iron core body 10. wearing the coil assembly 30a~30c to, Tsugitetsushinzai 20a, fitted and 20b to the magnetic path opening 10a _1, 10b ₁ of the iron core body 10. Thus sticking to the iron core body 10 by welding, Leakage of magnetic flux at the joint between the iron core body 10 and the yoke core materials 20a and 20b can be reduced, and the power conversion efficiency of the transformer can be significantly improved. Further, since both iron core materials are fixed by welding, a pressure welding fixture for both iron core materials is not required, and the iron core is sandwiched between the holding frames as in the conventional case, and the holding frames are fixed by bolts,
It is possible to eliminate the complicated work of tightening the nut to fix the iron core. As a result, the whole transformer can be made compact and the work of assembling the transformer can be simplified.

Further, the iron core body 10 and the yoke core material 20a,
20b has a structure in which the above-mentioned first and second thin iron plates 11 and 21 are stacked, respectively. As the first and second thin iron plates, one thin iron plate material 41 having a predetermined shape is cut and divided at predetermined portions. By using each of the divided pieces formed as described above, a plurality of first thin iron plates 11 forming the iron plate body 10 and a plurality of second thin iron plates 21 forming the yoke core materials 20a and 20b are formed.
Are laminated in a predetermined order so that the first and second thin iron plates 11 and 21 divided from the same thin iron plate material 41 face each other, so that the joint portion of the iron core body 10 and the yoke core materials 20a and 20b is joined. It is possible to almost eliminate the gap between the two and further reduce the leakage of magnetic flux.

Further, as the second thin iron plate constituting the yoke core material, the yoke core materials 20a and 20b are used as the iron core body 10.
The chamfered corners 211 of the thin iron plate are formed so that the grooves 212 are formed on the outer surfaces of the joints between the iron core body 10 and the yoke core materials 20a, 20b when mounted on the magnetic path open parts 10a ₁ and 10b _1. The iron core body 10 and the yoke core material 20 described above are used.
a and 20b, the welding iron wire 70 is arranged in the groove 212 on the outer surface of the joint portion, and this portion is spot-welded and fixed, so that the welding of the iron core body and the yoke core material is performed. It can be done easily and reliably.

In addition, 2 of the above coil assemblies 30a to 30c
Next coil, copper plate 31 forming a peripheral circuit around the iron core leg
Because of the structure in which a plurality of coils are superposed, the inductive reactance component of the transformer is canceled by the capacitance between the primary coil and the secondary coil, and the output voltage of the transformer rises immediately and rapidly. The output current can be supplied to the load, and the power factor can be greatly improved.

After assembly of the above transformer, FIG.
As shown in (b) and (b), the angle member 75 is held by further attaching the angle members 75 to the upper side of the iron core body 10 and the fixing bolts 51 of the yoke core members 20a and 20b on both sides of the upper part of the iron core 100. The transformer can be carried around and the handling of the transformer becomes convenient.

In the above embodiment, spot welding was used for welding the iron core body and the yoke core material. However, this is a roller type movable electrode instead of the fixed prismatic electrode as the positive welding electrode. It is also possible to use the above, and rotate and move this onto the welding iron wire to seam weld the joint between the iron core body and the yoke core material.

In the above embodiment, the three-phase inner iron core was taken as an example, but the type of the iron core is the center core type iron core (see FIG. 8).
(a)) or a single-phase inner iron core (Fig. 8 (b)) may be used. Figure 8
In (a), 80 is an iron core main body that constitutes the center core type iron core 100a. Here, the central iron core leg 80c to which the coil assembly 30 is attached is connected to the left and right iron core legs 80a and 80b to which no coil is attached. Compared with the iron core of the first embodiment, only the cross-sectional area is doubled. See also FIG.
In (b), 90 is a U-shaped iron core body that constitutes the single-phase inner iron-type iron core 100b. The coil assemblies 30a and 30b are attached to both sides facing each other, and the magnetic path opening portion, that is, the U-shape. A yoke core material 91 is fitted into the front opening 90a of the mold and fixed to the iron core body 90 by welding. In FIG. 8, bolts and nuts for holding the iron core body and the thin iron plate of the yoke core material are omitted.

Next, a second embodiment of the present invention will be described. FIG. 9 is an explanatory view of the transformer according to the second embodiment, and FIGS.
FIG. 12 is a diagram for explaining the assembly method. In the figure, the same reference numerals as those in the above-mentioned first embodiment indicate the same things,
Here, the E-shaped first auxiliary iron plate 15 is thicker than the first thin iron plate 11 on the front surface and the back surface side of the iron core body 10 and the opening shape of the magnetic path opening portion is slightly different from this. Is attached to the second thin iron plate 21 on the front and back surfaces of the yoke core members 20a and 20b, and is thicker than the second thin iron plate 21.
The second embodiment differs from the first embodiment only in that a second auxiliary iron plate 25 having a rectangular shape which can be fitted to the magnetic path open portions 15a ₁ and 15b ₁ of the auxiliary iron plate 15 is attached.

Next, the manufacturing method will be described. First above
A predetermined number of thin iron plates 11 are superposed, and then the first auxiliary iron plate 15 thicker than the thin iron plates is further overlapped on the front surface and the back surface of the first thin iron plate 11, and these bolt insertion holes 15a and 40a are formed. The iron core body 10 is configured by inserting the bolt 51 and screwing the nut 52 into the tip. A predetermined number of the second thin iron plates 21 are superposed, and then the second auxiliary iron plate 25 thicker than the thin iron plate is further superposed on the front surface and the back surface of the second thin iron plate 22, and these bolt insertion holes 25a are formed. , 40a are tightened with bolts 51 and nuts 52 to form the yoke core material 20 (FIG. 10).

Subsequently, each coil assembly 30 is attached to each of the left and right iron core legs 10c, 10e and 10d in the center of the iron core body 10.
c, 30b, 30a are attached (FIG. 11), and the yoke core materials 20a, 20b are fitted and attached to the two magnetic path opening portions 10a ₁ , 10b ₁ of the iron core body 10 (FIG. 12).
(a)). Then, the welding iron wires 70 are arranged in the V-grooves 212 formed by the chamfered portions 211 of the yoke core members 20a and 20b and the inclined surfaces of the tips of the iron core legs (FIG. 12).
(b)), Spot weld this part. This welding is performed in the same manner as in the first embodiment.

In addition to the effects of the above-described embodiment, the present embodiment having such a configuration has the first and second front and back surfaces of the iron core body 10.
On the thin iron plate 11, a first auxiliary iron plate 15 which is thicker than the first thin iron plate and in which the opening shape of the magnetic path open portions 15a ₁ and 15b ₁ is different from that is attached, and the front and back surfaces of the yoke core materials 20a and 20b are attached. Since the second auxiliary iron plate 25, which is thicker than the second thin iron plate and has a shape that can be fitted into the magnetic path opening openings 15a ₁ and 15b ₁ of the first auxiliary iron plate, is attached to the second thin iron plate 25, The yoke core materials 20a and 20b can be reinforced, and the yoke core material is made of iron by the inner surface of the first auxiliary iron plate 15 of the iron core body 10 and the outer surface of the second thin iron plate 2 of the yoke core materials 20a and 20b. It can be aligned with the core body, and positioning of both iron core materials becomes easy.

In each of the above embodiments, one thin iron plate material 41 is divided into one E-shaped first thin iron plate and two inverted trapezoidal second thin iron plates, and the first and second A plurality of thin iron plates are overlaid to form an iron core body 10 and yoke core materials 20a, 20.
b is shown, but the method of dividing the thin iron plate material is not limited to this. For example, the thin iron plate material is one E-type first thin iron plate and the second thin plate of the inverted trapezoid shape that is long in the lateral direction. You may divide into one iron plate. In this case, as shown in FIG. 13, one yoke core material 2 is provided in the magnetic path opening portion on the front surface of the E-shaped iron core body 10.
0 into the magnetic core opening 10a ₁ of the iron core body 10,
10b ₁ is closed by one yoke core material 20.

Further, in this case, the spot welding apparatus is not limited to the one shown in the above embodiment, but may be one in which two sets of positive and negative welding electrodes are arranged at a predetermined interval as shown in FIG. Good. In the figure, 270a ₁ and 270b ₁ are the first positive and negative welding electrodes, 270a ₂ and 270b ₂ are the second welding electrodes.
Of the positive and negative welding electrodes of the pressing spring member 27.
It is urged downward by 1a ₁ , 271b ₁ , 271a ₂ and 271b ₂ . When the iron core body 10 and the yoke core material 20 of FIG. 13 are welded using such a welding device, the interval between the left and right positive side welding electrodes 270a ₁ and 270a ₂ is set to the length of the yoke core material 20. According to this, the iron core body 10 and the yoke core material 20 can be joined by one welding.

Next, a third embodiment of the present invention will be described. 14A and 14B are views for explaining a transformer according to a third embodiment of the present invention, FIG. 14A is an external view of the transformer, and FIG. 14B is a perspective view of an iron core body of the transformer. FIG. 14 (c) shows a case where the yoke core material is fitted into the iron core body having the coil attached thereto. In the figure, reference numeral 301 denotes an iron core body, which is an E-type iron core portion 3 formed by stacking E-type thin iron plates.
10 and U-shaped upper and lower iron core parts 320 and 330 arranged on the upper and lower surfaces of the central leg 310c of the E-shaped iron core part 310 and formed by stacking U-shaped thin iron plates. Has been done. Further, the central iron core leg 310c of the E-shaped iron core part 310
310 between the left and right iron core legs 310b, 310a
The inner spaces 320c and 330c of the d and 310e and the U-shaped iron core parts 320 and 330 are used as coil housing spaces.

In this case, the central opening 340a of the square-shaped copper plate 340 is connected to the central iron core leg 310c of the E-shaped iron core 310 and the lower iron core leg 32 of the upper U-shaped iron core 320.
0b, a plurality of lower U-shaped iron core portions 330 are fitted into the upper iron core legs 330a to form a coil portion. Here, an insulating member is interposed between the copper plates, whereby the upper and lower copper plates are insulated, and the copper plates are appropriately connected in series or in parallel to form a primary coil and a secondary coil. .

Further, 301d and 301e are respectively the above E
Yoke core material fitted and welded and fixed to the magnetic path opening portions 310d ₁ and 310e ₁ of the iron core portion 310, and 302 and 303 are magnetic path opening portions 320 of the E-shaped iron core portion 310, respectively.
a _1, fitted to 330a ₁ is a yoke core which is welded and fixed. Here, as shown in FIG. 14 (d), the copper plate coil has a notch 35 at one corner of the copper plate coil 350.
1 is used so that it can be connected to another copper plate coil, and the others constitute the coil portion as in the first embodiment.

In this embodiment, the iron core body 3 is
01 is an E-type iron core body 31 formed by laminating E-type thin iron plates
0 and U-shaped iron core parts 320 and 330 which are arranged on the upper and lower surfaces of the central leg 310c of the E-shaped iron core part 310 and are formed by laminating U-shaped thin iron plates. Spaces 310a and 310b between the iron core legs of the E-shaped iron core portion 310 and internal spaces 320a and 33 of the upper and lower U-shaped iron core portions 320 and 330.
0a is used as the coil housing space, and the magnetic path opening portions 310a ₁ , 310b ₁ , 32 of the E-shaped iron core portion and the U-shaped iron core portion are provided.
0a ₁ and 330a ₁ respectively include yoke core materials 301d, 301e and 302 that form a closed magnetic circuit with the iron core portions.
Since 303 and 303 are fitted and welded and fixed, in addition to the effect of the first embodiment, four sides of the coil are surrounded by iron cores, which reduces leakage of magnetic flux generated in the coil and shortens the magnetic path. The magnetic resistance is reduced, and the power conversion efficiency of the transformer can be significantly improved.

In each of the above embodiments, the copper plate coil is used for both the primary coil and the secondary coil. However, the present invention is not limited to this. For example, the primary and secondary coils are overlapped with strip-shaped conductors. The coil having such a structure may be used only for the primary coil and the primary coil, and for the secondary coil, a coiled strip-shaped copper plate or a copper plate coil may be used. Further, as shown in FIGS. 15 (a) and 15 (b), a copper plate coil 340 is used as a secondary coil, and the copper plate secondary coil 3 is attached to each fold portion 371 of an insulating material 370 in which an insulating mount is formed in a bellows shape.
40 may be arranged every other fold, and the enamel wire 380 may be arranged as a primary coil between the upper and lower copper plate secondary coils (FIGS. 15 (c) and (d)).

Further, the transformer of the present invention described above has the effect of advancing the secondary side load current, and therefore, the spot welding apparatus (filed on April 4, 1991) already filed by the applicant of the present application. It can also be used as a power supply device.

As a fourth embodiment of the present invention, a spot welding apparatus using the transformer of the first embodiment as a power supply device will be described below. FIG. 16 (a) is a schematic diagram showing the configuration of the spot welding apparatus. In the figure, 100S is a spot welding apparatus, which includes a single-phase AC power supply 101, a transformer 1 for transforming the output, and the single-phase AC power supply. It is composed of a power supply unit 120 including an on / off switch circuit 102 inserted between the transformer 1 and a spot welding unit 130 including a pair of welding electrodes 110 and a member 111 to be welded sandwiched by the welding electrodes. ing. Here, the transformer 10
0 is the transformer of the first embodiment shown in FIG. 8A, 124 is a primary coil in which copper plate coils are connected in series, and 123 is a secondary coil in which copper plate coils are connected in parallel. .

Next, the function and effect will be described. First, as shown in FIG. 16 (b), the material to be welded 111 is pressed and sandwiched by the pair of welding electrodes 110, and the switch circuit 102 is turned on. Then, the AC output of the AC power supply 101 is applied to the primary coil 124 of the transformer 1, and the secondary coil 123 generates a voltage according to the winding ratio of the primary and secondary coils due to the principle of electromagnetic induction. As a result, a voltage on the secondary side is applied to the pair of welding electrodes 110, a welding current I flows through the member to be welded 111 as shown in FIG. 16 (c), and the heat generated at that time causes the pressure contact portion A of the electrodes to move. It is heated and melted and joined.

In the spot welding apparatus using the transformer having such a configuration, copper plates are stacked as a secondary coil, and the inductive reactance of the transformer is generated by the electrostatic capacitance generated between the primary coil and the secondary coil. Since the components are offset, the welding current can be advanced. That is, conventionally, as shown in FIG. 17, the phase of the welding current I ₂ is
While the output voltage V _{0 was} delayed due to the inductive reactance component of the transformer and the rising was slow, in the present embodiment, the welding current I ₁ is the output voltage V _{0 of the} transformer.
At the same time as the occurrence of the electric current, a steep rise occurs, and a large current I ₁ having a steep rise flows through the member to be welded sandwiched by the welding electrodes.

As a result, the welded portion of the member to be welded is efficiently heated and melted sufficiently, and strong spot welding resistant to vibration can be performed. Specifically, even if oil or dust adheres to the welded surface of the workpiece, it can be welded without problems even if the welded surface is a little rough. The work can be omitted. Further, spot welding can be performed even if a sealer or an adhesive agent for preventing the infiltration of moisture is applied to the welded surface of the aluminum plate as long as it is completely dried. Further, in spot welding of aluminum plates having different thicknesses, the limit of the thickness of the thick plate and the thin plate is usually about 3 to 1, whereas in the present embodiment, the thin aluminum foil of 0.1 mm is 100 times thicker than this. It can also be spot welded to a 10 mm thick aluminum plate. As an example of welding when the thicknesses are different, for example, as shown in FIG. 18 (a), a bone member 111c and an aluminum plate 111d are welded. Of course, an adhesive agent 111e is interposed between these members. However, if it is before it dries, welding can be done without problems. As another example, FIG. 18B shows a case where an aluminum plate 111d is spot-welded to the upper surface and the lower surface of the I-shaped steel material 111f at the same time.

110a is a secondary coil 123 of the transformer.
It is an auxiliary copper electrode that is connected to the middle point and that allows spot welding current to flow efficiently. As another example, FIG. 18 (c)
The auxiliary copper electrodes 11 on both sides of the central vertical side of the I-shaped steel material.
0a is arranged.

Furthermore, with aluminum foil or titanium foil, spot welding of 20 sheets is possible, and copper alloy, platinum,
Such overlay welding is also possible for non-ferrous metals such as gold and silver.

To give a concrete example, in the case of aluminum in the past, spot welding of oil, dust, etc. could not be carried out as it is, so normal oil was washed, washed with water, dried and welded within 2 hours. In addition, especially for important members used for aircraft etc., which require reliability,
In the present invention, welding is performed within one hour, whereas in the present invention, even if oil or dust is adhered to the surface of the member to be welded, or a sealer material for watertightness is applied, or adhesion is performed. Even if the agents are applied over the entire surface, spot welding can be performed as they are before they are dried.

If the adhesive or sealer material is dried, it can be welded by using a spot welding apparatus (Japanese Patent Publication No. 52-1379) using two pairs of upper and lower welding electrodes.
FIG. 19 shows a fifth embodiment of the present invention in which the transformer of the first embodiment is used in this spot welding apparatus. In the figure, 110c and 110d are connected to the secondary coil 123 of the first transformer 1a. First pair of welding electrodes, 110
f and 110g are the secondary coils 123 of the second transformer 1b.
With a second pair of welding electrodes connected to each other, the members to be welded 111g and 111h having the dried insulating film interposed therebetween are superposed and welded by these two sets of welding electrodes. Here, each of the first and second transformers has the same configuration as the transformer of FIG. 8 described above, and the primary coil 124 of each transformer is provided with a switch circuit (not shown) as in the above embodiment. It is connected to a single-phase AC power source.

In welding by this apparatus, first, a current IP flows laterally between adjacent electrodes, and the heat generation action thereof melts or carbonizes the insulating film 111g. As a result, a pair of upper and lower welding electrodes 111c, 111d, 111e,
A welding current flows between 111f and spot welding is performed.
In this way, spot welding can be performed even if there is an insulating film or the like between the members to be welded.

Further, in this apparatus, as shown in FIG. 20, the dried adhesive 111a is placed between the aluminum plates 111 which are superposed on each other.
Even if there is such a problem, welding can be performed without problems up to about three layers. FIG. 20 (a) shows the state of the cross section of the member to be welded before welding and FIG. 20 (b) shows the state of the welded member after welding.

Further, as shown in FIG. 21, when four or more aluminum plates are stacked and there is an insulating film between the plates, it is necessary to adjust the time until the central insulating film 111b is carbonized and becomes conductive. Overlap welding is possible, and when the insulating film is oil or the like, multi-layer spot welding of about 10 sheets can be performed. 21 (a) shows the state of the cross section of the member to be welded before welding and FIG. 21 (b) shows the state of the cross section of the member to be welded.

An example of a specific application of such superposition spot welding is the same as that of the above-mentioned prior application, and is omitted here.

Furthermore, the spot welding apparatus can be used for joining aluminum plate members constituting an aircraft. That is, in the past, most aircraft accidents were in cases where cracks occurred from the holes in the tacks that resulted in accidents.Since the size of the aircraft has increased in recent years, the vibration power has also increased. However, it is more likely to cause metal fatigue, but in the spot welding of the present invention,
Since the spot welds are sufficiently melted and joined firmly,
It is highly reliable and can be used for joining members instead of the conventional tacking, which not only eliminates the need for troublesome work such as tacking, but also eliminates the tack holes that have been a problem with tacking. Accidents due to metal fatigue can be avoided. Further, such a spot welding apparatus of the present invention can be widely used in future automobile manufacturing in which an aluminum plate will be adopted.

Further, in the spot welding apparatus of the fourth or fifth embodiment, as described in detail in the specification of the prior application, the welding electrode is pressed in synchronization with the welding current, so that the member to be welded Pressurization can be effectively performed.

Further, the butt welding method of the rod-shaped body, which is a kind of resistance welding similar to the spot welding, enables the welding effect of 6 times, that is, the welding of the member to be welded which is 6 times thicker than the conventional one. . Specific examples of this butt welding include T-shaped butt welding of an aluminum pipe or the like and butt welding by intersecting two pipes, which is also the same as that described in the specification of the prior application. Therefore, it is omitted here.

Next, as a sixth embodiment of the present invention, a spot welding apparatus using a sawtooth single-phase output power supply apparatus will be described. FIG. 22 (a) is a configuration diagram of the spot welding apparatus, and the power source thereof is based on the power source apparatus (Japanese Patent Application No. 2-150585) already filed by the applicant. In the figure, 501 is a three-phase AC power source, 504
Is a phase control circuit for controlling the supply of the three-phase AC power so as to perform only the range of 120 to 180 degrees for each phase, 1 is three primary coils 505 to 507, and three secondary coils 531 to 5
The transformer of the first embodiment having the iron core 100 on which 33 is mounted, 12 is ground, and 500 is a power supply device including the phase control circuit 504 and the transformer 1. Further, in the phase control circuit 504, in the figure, 520a, 520b, 520
c is a thyristor, 521 is a zero-cross point detector for detecting the zero-cross point of the sine wave of each phase of the three-phase alternating current, 522a, 52.
Reference numerals 2b and 522c are phase adjusters that receive the output of the zero-cross point detector 521 and adjust the firing angles of the thyristors 520a, 520b, and 520c of each layer.

Here, the primary coils 505 to 507 are used.
And the secondary coils 531 to 533 are one of the coil assemblies 30a to 30c attached to the respective iron core legs of the E-type iron core body.
Secondary coil and secondary coil, and secondary coils 531-5
33 are all connected in parallel, both ends of which are connected to the pair of spot welding electrodes 110, and the primary coils 505 to 50
7, one end of each of the thyristors 520a to 520 is
It is connected to c and the other end is grounded.

Next, the operation will be described. The energization from the three-phase AC power supply 501 to the three-phase coils 505 to 507 of the transformer 1 is controlled by the phase controller 4, and the first, second, and third coils 505, 506 are controlled as shown in FIG. 22 (b). , 50
7 shows the phase angles 12 of AC sine waves X, Y, Z of each layer.
Each coil is energized only in the range of 0 to 180 degrees (c and f for X, b and e for Y, and a and d for Z), and the coils are open for the rest of the time. Is.

When the three-phase first, second, and third coils 505, 506, and 507 are sequentially energized in this manner, the triple-frequency wave is generated in the iron core as shown in FIG. 22 (c). A magnetic flux having a drooping characteristic is induced, and as a result, the secondary coil 53
Similarly, a current having a triple frequency of a sawtooth wave as shown in FIG. 22 (c) is induced in 1 to 533.

Then, the sawtooth-shaped triple frequency current is applied to both welding electrodes 110 of the welded portion 130, and the current is applied to the corresponding portions of the welding member 111 sandwiched between the both welding electrodes 110, so that the portions are It melts and spot welding is performed. At this time, the following effects are obtained in addition to the effects of the first embodiment.

Generally, spot welding requires a large amount of electric current, and a problem of three-phase imbalance occurs in the conventional method using a single-phase alternating current. However, in the present embodiment, three-phase is converted into a single-phase. The problem of three-phase imbalance does not occur. Further, since the single-phase output has a sawtooth wave at a triple frequency as shown in FIG. 22 (c), extremely high quality welding can be performed. In particular, non-ferrous metals such as Al, Cu, and Bs can be welded well, and spot welding is possible even if there is a small amount of insulating film.

Since the frequency obtained by the power source used in the present invention is tripled, the size of the transformer is reduced and the weight is reduced to the conventional one.
It is only / 3, and it is very small and lightweight. In addition, since the structure of the transformer is simple, small and lightweight, the manufacturing cost can be reduced significantly.

The firing angle of a one-phase AC sine waveform is set to 120
The strength of spot welding can be greatly adjusted by appropriately adjusting the front and back around the degree.

By performing automatic control by a computer, fine adjustment can be performed as compared with the conventional commercial frequency, and great welding stability can be obtained. The waveform of the welding current is not limited to that described above, and by adjusting the phase control circuit, for example, a welding current having a waveform as shown in FIGS. 23 (a) to 23 (c) can be obtained.

Although the embodiment in which the transformer of the present invention is used for resistance welding has been described above, since the present transformer is naturally provided with drooping characteristics, it can be efficiently used in arc welding as well as resistance welding and is extremely stable. It is possible to work with various arcs, and this transformer has an outstanding effect as a power source for precision motors, vibrators, and photothermal equipment.

[0083]

As described above, according to the transformer and the method of manufacturing the same according to the present invention, the iron core of the transformer and the iron core main body having the coil accommodation space inside and a part of the magnetic path opened. A coil assembly that can be fitted into a magnetic path opening portion of the iron core body and that forms a closed magnetic path together with the iron core body, and a coil assembly in the coil housing space of the iron core body. Since it is installed and the yoke core material is fixed to the iron core body by welding, the leakage of magnetic flux at the joint between the iron core body and the yoke core material can be reduced, and the power conversion efficiency of the transformer can be greatly improved. Can be improved. Further, since both iron core materials are fixed by welding, there is no need for a press-contacting fixing tool for both iron core materials, which makes it possible to make the entire transformer compact and simplify the transformer assembly work.

Further, according to the present invention, the iron core body and the yoke core material are structured by laminating the first and second thin iron plates, respectively, and the first and second thin iron plates have predetermined shapes. A plurality of first thin iron plates forming the iron plate main body and a plurality of second thin plates forming the yoke core material are used by using each divided piece formed by cutting one thin iron plate material at a predetermined portion and dividing the thin iron plate material. Since the iron plate and the first and second thin iron plates divided from the same thin iron plate material are laminated in a predetermined order when the yoke core material is attached to the magnetic path opening portion of the iron core body, It is possible to almost eliminate the gap at the joint portion between the iron core body and the yoke core material, and further to reduce the leakage of magnetic flux.

Further, according to the present invention, on the first thin iron plate on the front surface and the back surface of the iron core body, the first auxiliary iron plate which is thicker than the first thin iron plate and whose opening shape of the magnetic path opening portion is different from the first auxiliary iron plate. A second auxiliary iron plate that is attached in a stacked manner and is thicker than the second thin iron plate on the front and back surfaces of the yoke core material and that can be fitted into the magnetic path opening opening of the first auxiliary iron plate. Since the iron core body and the yoke core material can be reinforced by stacking, the yoke core material can be aligned with the iron core body by the auxiliary iron plate inner surface and the thin iron plate outer surface. Positioning of both iron core materials becomes easy.

According to the invention, the iron plate body is
An E-shaped iron core part formed by stacking E-shaped thin iron plates, and a U-shaped iron core arranged on both sides of the center leg of the E-shaped iron core part and formed by stacking U-shaped thin iron plates And the inner space of the upper and lower spaces of the E-shaped iron core and the inner spaces of the upper and lower U-shaped iron cores are defined as the coil accommodating space. Since the yoke core material forming a closed magnetic circuit with each of the iron core portions is fitted and welded and fixed to the magnetic path open portion of the mold iron core portion, the four sides of the coil are surrounded by the iron core,
The leakage of the magnetic flux generated in the coil is reduced, the magnetic path is shortened, the magnetic resistance is reduced, and the power conversion efficiency of the transformer can be significantly improved. In addition, since the iron core body and the yoke core material are joined by welding, there is no need for a device to hold these iron core members in pressure contact, and the transformer can be made compact. It is possible to eliminate the complicated work of sandwiching the holding frame and further tightening the holding frame with bolts and nuts to fix the iron core. As a result, the transformer can be manufactured with good workability.

According to the present invention, as the second thin iron plate constituting the yoke core material, when the yoke core material is attached to the magnetic path opening portion of the iron core body, the iron core body and the yoke core material As a groove is formed on the outer surface of the joint portion with, a thin iron plate corner portion is chamfered, the iron core body and the yoke core material, the yoke core material is attached to the iron core body, A metal rod for welding is placed in the groove on the outer surface of the joint, and spot welding or seam welding is performed on this portion, so that the iron core body and the yoke core material can be welded easily and reliably. There is an effect that can be.

Further, according to the resistance welding device of the present invention, the transformer having the above structure is used as the transformer of the power supply device, and the secondary coil of the coil assembly is provided with the capacitance between the primary coil and the secondary coil. In order to cancel out the inductive reactance component of the transformer by the above, it is configured by stacking multiple copper plates that form a peripheral circuit around the iron core leg, and a welding current that rises sharply at the same time as the output voltage is generated is applied to the welding electrode. Since it is supplied, at the same time when the output voltage of the transformer is generated,
A large current with a steep rise flows through the work piece sandwiched between the welding electrodes, which may cause some insulation film on the surface of the work piece, or some of the work pieces to overlap. Even if there is, there is an effect that the welded portion can be sufficiently heated and melted to perform strong welding resistant to vibration.

Further, according to the present invention, as the welding electrodes, two pairs of upper and lower welding electrodes are arranged close to each other, and the above-mentioned transformers are provided for the respective welding electrodes of each pair, and each adjacent pair of welding electrodes is provided. Since it was connected between the upper welding electrodes and between the lower welding electrodes so that an electric current can flow through the upper welded member and the lower welded member, respectively. Even if an insulating film is present, the above-mentioned insulating film is melted or carbonized by the heat generation effect of the current flowing between the adjacent welding electrodes to establish a state in which conduction can be established between the upper and lower welding electrodes, thereby performing resistance welding. There is an effect that can be.

Further, according to the present invention, the iron core of the transformer of the resistance welding apparatus is a single-phase iron core, and the primary side of the single-phase iron core is provided with a three-phase primary coil on the secondary side. Since the secondary coil of the phase is mounted by winding, the phase of the three-phase alternating current is controlled by the phase control circuit, the primary coil of the three-phase is supplied, and the single-phase alternating current is output to the secondary coil. By controlling the phase of each phase of the three-phase alternating current, it is possible to obtain a composite waveform equivalent to a single-phase output of a sawtooth wave at triple frequency. A phase output can be produced. Further, by controlling the phase, there is an effect that the obtained output waveform can be made a waveform suitable for spot welding.

[Brief description of drawings]

FIG. 1 is a diagram showing a structure of a transformer according to an embodiment of the present invention.

FIG. 2 is a diagram showing a method of forming a thin iron plate used for the iron core of the transformer.

FIG. 3 is a diagram showing a process of forming an iron core body and a yoke core material by stacking the thin iron plates.

FIG. 4 is a diagram showing a structure of a coil assembly mounted on the iron core of the transformer.

FIG. 5 is a diagram showing a process of mounting the coil assembly on the iron core body of the transformer.

FIG. 6 is a diagram showing a process of mounting and fixing a yoke core material on the iron core body of the transformer.

FIG. 7 is a view showing the transformer of the first embodiment with an angle member attached as a handle.

FIG. 8 is a view showing a center core type iron core and an inner iron type iron core as a modified example of the first embodiment.

FIG. 9 is a diagram showing a transformer according to a second embodiment of the present invention.

FIG. 10 is a diagram showing a step of forming an iron core body and a yoke core material of the transformer by stacking thin iron plates.

FIG. 11 is a diagram showing a step of mounting the coil assembly on the iron core of the transformer.

FIG. 12 is a diagram showing a step of mounting and fixing a yoke core material on an iron core body of the transformer.

FIG. 13 is a diagram showing another example of the split type E-type iron core described in the first and second embodiments, in which one yoke core material is used.

FIG. 14 is a diagram showing an iron core structure of a transformer according to a third embodiment of the present invention.

FIG. 15 shows a modified example of the transformer of the third embodiment.
It is a figure which shows what uses a copper plate coil as a secondary coil, an enamel wire as a primary coil, and a bellows-shaped insulating mount as a member which insulates both coils.

FIG. 16 is a diagram showing a resistance welding device according to a fourth embodiment of the present invention.

FIG. 17 is a diagram showing a relationship between an output voltage and an output current of a transformer applied to a welding electrode of the spot welding apparatus.

FIG. 18 is a diagram showing an example of welding members having different thicknesses.

FIG. 19 is a view for explaining the resistance welding device according to the fifth embodiment of the present invention.

FIG. 20 is a diagram showing a three-layer lap welding method for aluminum plates having an insulating film.

FIG. 21 is a diagram showing a four-layer lap welding method for aluminum plates having an insulating film.

FIG. 22 is a view for explaining a spot welding device according to a sixth embodiment of the present invention.

FIG. 23 is a diagram showing an example of a waveform of a welding current that can be generated by the power source of the sixth embodiment device.

FIG. 24 is a view showing a structure of a conventional E, E-type split iron core.

FIG. 25 is a view for explaining the structure of a conventional cut core type iron core.

FIG. 26 is an explanatory diagram of problems in the conventional bonded aluminum plate.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Transformer 10 Iron core main body 10a, 10b Coil accommodation space 10a ₁ , 10b ₁ Magnetic path open part 10c, 10d, 10e Central iron core leg 11 1st thin iron plate 12 Fixing bolt, nut 20a, 20b Yoke core material 21 1st 2 thin iron plate 30a, 30b, 30c coil assembly 40, 41 thin iron plate material 100 iron core 100S spot welding device 101 AC power supply 102 switch circuit 110 welding electrode 111 welded material 501 three-phase AC power supply 504 phase control circuit 505-507 1 Secondary coil 531 to 533 Secondary coil

[Procedure amendment]

[Submission date] October 13, 1994

[Procedure Amendment 1]

[Document name to be corrected] Drawing

[Correction target item name] All drawings

[Correction method] Change

[Correction content]

[Figure 1]

[Fig. 2]

[Figure 3]

[Figure 9]

[Figure 4]

[Figure 5]

[Figure 8]

[Fig. 13]

[Figure 6]

[Figure 7]

FIG. 16

FIG. 17

[Figure 10]

FIG. 11

FIG. 19

FIG. 20

FIG. 21

FIG. 25

[Fig. 12]

FIG. 14

FIG. 22

FIG. 23

FIG. 15

FIG. 18

FIG. 26

FIG. 24

Claims (14)

[Claims] 1. An iron core main body formed by stacking a plurality of first thin iron plates of the same shape, having a coil accommodation space therein, and a part of a magnetic path being open, and a coil accommodation space of the iron core main body. A ring-shaped coil assembly, which is mounted inside, and a combination of a primary coil and a secondary coil, and a plurality of second thin iron plates of the same shape are laminated and fitted into the magnetic path opening portion of the iron core body. A transformer provided with a yoke core material fixed by welding and forming a closed magnetic path with the iron core body. 2. The transformer according to claim 1, wherein the first thin iron plate and the second thin iron plate are divided pieces obtained by cutting one thin iron plate material having a predetermined shape at predetermined portions. And a plurality of first thin iron plates constituting the iron core body and a plurality of second thin iron plates constituting the yoke core material are obtained by dividing the same thin iron plate material , A transformer characterized in that the second thin iron plates are laminated in a predetermined order so as to face each other. 3. The transformer according to claim 2, wherein the second thin iron plate constituting the yoke core material has a groove formed on an outer surface of a joint portion between the iron core body and the yoke core material. A transformer characterized in that its corners are chamfered. 4. The transformer according to claim 2, wherein the iron core main body is disposed on the front and back surfaces of the first thin iron plate and is thicker than the first thin iron plate and the opening of the magnetic path open portion. A first auxiliary iron plate having a different shape is provided, and the yoke core material is arranged on the second thin iron plate on the front surface and the back surface thereof, is thicker than the second thin iron plate, and opens the magnetic path of the first auxiliary iron plate. A transformer having a second auxiliary iron plate having a shape that can be fitted into the opening. 5. The transformer according to claim 1, wherein the iron plate main body is arranged on both side surfaces of an E-type iron core portion formed by stacking E-type thin iron plates and a central leg of the E-type iron core portion. , The U-shaped iron cores formed by stacking U-shaped thin iron plates are combined, and the upper and lower internal spaces of the E-shaped iron cores and the interiors of the upper and lower U-shaped iron cores are combined. A space is defined as the coil accommodating space, and the magnetic path open portions of the E-shaped iron core portion and the U-shaped iron core portion form a yoke magnetic core material that forms a closed magnetic circuit with each of the iron core portions. A transformer that is fitted and welded and fixed. 6. The transformer according to claim 1, wherein the coil assembly is formed by cutting a copper plate to form a peripheral circuit and cutting a part of the peripheral circuit to form an iron core. A transformer characterized in that copper plates for primary and secondary coils that can be attached to legs are alternately laminated with an insulating film interposed therebetween. 7. An iron core body assembling step of assembling a plurality of first thin iron plates having the same shape to assemble an iron core body having a coil accommodation space therein and a part of a magnetic path being open, A yoke core material that is fitted into the magnetic path opening portion of the core body and forms a closed magnetic path with the iron core body is formed into a second core of the same shape.
A yoke iron core material assembling step of stacking a plurality of thin iron plates and assembling, and a coil attaching step of attaching a ring-shaped coil assembly formed by combining a primary coil and a secondary coil in the coil accommodating space of the iron core body. , Fitting the yoke core material into the magnetic path opening portion of the iron core body,
And a welding step of resistance welding the surfaces of these joints. 8. The method for manufacturing a transformer according to claim 7, wherein each of the first thin iron plate and the second thin iron plate is obtained by cutting one thin iron plate material having a predetermined shape at predetermined portions and dividing the thin iron plate material. A plurality of first thin iron plates that compose the iron core body and a plurality of second thin iron plates that compose the yoke core material are divided into pieces by using split pieces, and the yokes are provided in the magnetic path opening portion of the iron core body. A method for manufacturing a transformer, characterized by stacking in a predetermined order such that first and second thin iron plates divided from the same thin iron plate material face each other when a core material is mounted. 9. The method of manufacturing a transformer according to claim 7, wherein in the iron core body assembling step, the first thin iron plates are laminated, and the first thin iron plates on the front surface and the back surface of the laminated body are formed on the first thin iron plates. 1 is a step of stacking and arranging a first reinforcing iron plate that is thicker than the thin iron plate and has a different opening shape of the magnetic path open portion, and in the yoke core material assembling step, the second thin iron plate is laminated and A step of stacking a second reinforcing iron plate thicker than the second thin iron plate and having a shape that can be fitted into the magnetic path opening of the first reinforcing iron plate on the second thin iron plate on the front surface and the back surface of the laminate. There is provided a method for manufacturing a transformer, characterized in that, when the yoke core material is mounted on the iron core body, the yoke core material is positioned by contact between the inner surface of the reinforcing iron plate and the outer surface of the thin iron plate. 10. The method of manufacturing a transformer according to claim 7, wherein the second thin iron plate constituting the yoke core material is iron when the yoke core material is attached to a magnetic path opening portion of the iron core body. Use a thin iron plate corner chamfered so that a groove is formed on the outer surface of the joint between the core body and the yoke core material.The iron core body and the yoke core material are joined to the iron core body. An iron core material is mounted, a welding metal rod is arranged in a groove on the outer surface of the joint portion, and a positive electrode side prismatic electrode having the same length as the welding metal rod is pressure-welded to the welding metal rod and the welding electrode. A transformer characterized in that a negative electrode welding electrode having the same shape as the above is pressure-welded on the yoke core material in the vicinity of the joint, and in this state, a welding current is applied to both the welding electrodes to spot-weld the joint. Manufacturing method. 11. The transformer according to claim 10, wherein
A roller type movable electrode instead of the positive electrode side prismatic electrode,
An electrode having a predetermined shape is used in place of the negative electrode side prismatic electrode, the negative electrode side electrode is fixed to the iron core body or the yoke core material, and the roller type movable electrode is rotatively moved on the welding metal rod. At the same time, a welding voltage is applied to this to seam weld the above-mentioned joint portion. 12. A transformer, which receives an AC input and outputs a welding voltage and current, and a pair of welding electrodes, to which the output of the transformer is applied and which perform resistance welding by pressing and sandwiching a member to be welded. A resistance welding apparatus for performing resistance welding of a non-ferrous metal material, wherein the transformer is formed by stacking a plurality of first thin iron plates having the same shape, and has a coil accommodation space therein, An iron core body with an open portion, and an iron core leg that is mounted in the coil housing space of the iron core body so that the inductive reactance component of the transformer is canceled by the capacitance between the primary coil and the secondary coil. A secondary coil formed by stacking a plurality of copper plates forming a peripheral circuit around the
A ring-shaped coil assembly having a primary coil mounted between secondary coils and a plurality of second thin iron plates of the same shape are laminated, and fitted into the magnetic path opening of the iron core body by welding. A resistance, which is fixedly provided with a yoke core material that forms a closed magnetic circuit with the iron core body, and supplies a welding current that sharply rises at the same time when an output voltage is generated to the welding electrode. Welding equipment. 13. The resistance welding apparatus according to claim 12, wherein welding is performed between the members to be welded via an insulator, and as the welding electrodes, two pairs of upper and lower welding electrodes arranged in close proximity are provided. , The above-mentioned transformers are provided respectively corresponding to the welding electrodes of each set, and the upper and lower paired welding electrodes of each set and the secondary coils of the transformers corresponding to these are welded to the upper welding electrodes adjacent to each other at the initial stage of welding. A resistance welding apparatus, wherein wires are connected so that an electric current can flow between them and between the welding electrodes on the lower side through the member to be welded on the upper side and the member to be welded on the lower side, respectively. 14. The resistance welding device according to claim 12, further comprising a phase control circuit for controlling the supply of a three-phase AC power supply for each phase, wherein the iron core of the transformer has three phases on the primary side. The primary coil of 2
A single-phase iron core in which a single-phase secondary coil is wound on the secondary side, and the three-phase primary coil of the transformer is connected to each phase of a three-phase AC power source through the phase control circuit. A resistance welding device characterized in that the phase control circuit controls the phase of each phase of a three-phase AC power source and outputs a single-phase AC to the secondary coil.