JPH11340069A - Manufacture of transformer - Google Patents

Abstract

PROBLEM TO BE SOLVED: To eliminate an influence of dimensional variation on the electromagnetic properties of an iron core by separating a square cylindrical or double square cylindrical iron core in the midway, providing a notch at the corner on hollow part side and developing the iron core like a line substantially. SOLUTION: In this method for manufacturing a transformer, a plurality of steel plates comprising an iron core forming member 11 are laminated to manufacture an iron core 1 first. In this case, the iron core 1 is separated at a separating section 12, and leg parts 2 and connecting parts 3 are formed alternately with a notch 13 interposed, and then connecting parts 14... are formed so as to have an arculate upper edge. Next, in the state where the iron core 1 is developped linearly before assembly, the iron core forming member 11 is turned on the center of its section and the leg part 2 is wound directly around a lead wire 7. Then the connecting part 14 is bent so that the notches 13 of the member 11 may be adhered with each other, and as a result, the laminated body of the member 11 has substantially a right-angled corner. Further, the position and shape of the connecting part 14 are selected as necessary, so that chamfering or rounded condition can be realized.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a transformer, and more particularly, to eliminating the influence of dimensional variations on the electromagnetic characteristics of an iron core, improving the material yield of thin steel sheets, and furthermore, connecting a winding to a core leg. The present invention relates to a method for winding with a high occupancy.

[0002]

2. Description of the Related Art A conventional iron core of a transformer is formed by combining a laminate of strip-shaped thin steel plates in a cross-girder shape, or a C-type having two legs or an E-type having three legs. It is manufactured by a method such as combining two cores in which steel plates are laminated and facing each other.

[0003]

However, according to the conventional manufacturing method, the mating side is randomly extracted and combined, so if there is a variation in dimensions, a gap is formed in the joined portion to increase the magnetic resistance. There was a problem.

[0004] Even if it is desired to wind the winding directly around the legs in order to obtain a high space factor of the conductor, it is difficult to do so. Therefore, it is necessary to wind the bobbin and insert it between the legs. Further, the C-type core and the E-type core need to be manufactured by stamping a thin steel plate. However, due to the shape, there is a problem that the material yield is low and the cost is high.

The present invention has been made to solve the above-mentioned drawbacks. A first object is to eliminate the influence of dimensional variations on the magnetic characteristics of the iron core, a second object is to improve the material yield, and The object of the invention is to enable the winding to be wound directly on the legs of the iron core with a high occupancy.

[0006]

SUMMARY OF THE INVENTION Accordingly, a method of manufacturing a transformer according to the present invention is directed to a square-tube-shaped core comprising left and right legs and upper and lower yoke portions and having one square hollow portion. When manufacturing a transformer in which windings are wound on the legs of the rectangular core, the rectangular core is separated on the way and cut into each corner of the hollow core side of the rectangular core. Producing the core material in the shape of the legs and the yoke portion being developed substantially linearly through the connecting portion using a thin steel plate, laminating a plurality of the core materials, After winding the winding around the legs of the laminated core material, the laminated body of the iron core material is bent at each of the plurality of connecting portions to close the square tubular shape, and the separation is performed. The fixed portions are fixed to each other.

Further, a method for manufacturing a transformer according to the present invention
A transformer is manufactured by winding a winding around a leg of a double-sided cylindrical core having two left and right yoke portions and upper and lower yoke portions and two square hollow portions. In the meantime, the above-mentioned double-angle cylindrical core is separated at the boundary portion with the upper or lower yoke portion of the central leg portion and the boundary portion with the central leg portion of the lower or upper yoke portion, and A cut is provided at each corner of the hollow core side of the cylindrical iron core, and the leg and the yoke are expanded substantially linearly through the connecting part using a thin steel plate as a core material. After manufacturing and laminating a plurality of the core core materials, and winding them around the legs of the laminate of the core core materials, bending the laminate of the core core materials at the plurality of connecting portions. , Thereby closing the double-sided cylindrical shape and fixing the separated portions to each other.

One of the features of the present invention is that a rectangular or double rectangular core is separated in the middle, and a notch is provided at a corner on the hollow side so that the core is developed substantially linearly. It is in the point which was made. As a result, the plurality of legs and the yoke constituting the iron core are connected to each other, and it is guaranteed that the material lot is always the same. As a result, the influence of the dimensional variation on the electromagnetic characteristics of the iron core is eliminated, and Can achieve the purpose.

Another feature of the present invention resides in that the iron core material is formed in a substantially linear shape. Thereby, the useless material at the time of press punching of a thin steel plate is reduced, the material yield is improved, and the second object can be achieved.

Further, since the iron core is linearly developed, the conductive wire and the needle of the winding machine do not interfere with other legs, and a high space factor is secured and the legs are directly and easily mounted on the legs. The conductor can be wound, and the third object can be achieved. In winding the conductor around the leg, the conductor is rotated around the center of the cross-section of the substantially linear laminated body of the core material, so that the conductor is wound on the leg of the laminated body of the core material. Can be adopted.

After completion of the winding, the iron core material is closed, and the separated ends are fixed to each other. Any of the following methods can be employed for the fixing. That is, it is possible to adopt a method of fixing only one portion of the separated end portions that is mutually matched by using the YAG laser welding method or another welding method. That is, the separated portions of the laminated body of the closed iron core members may be fixed by welding.

When the number of production lots is small and it is economically difficult to introduce a welding device, holes are provided at each of the separated ends, and a clamp-shaped coupling tool (for example, a U-shaped bracket) is inserted into the holes. Can also be fixed. That is, in each of the separated portions of the core material laminate, a hole is formed during or after the production of the iron core material, and after closing the core material laminate,
The separated portions may be fixed to each other by inserting a clamp-shaped coupling tool into the hole. In this case, the shape of the connector is not particularly limited.

Further, a projection may be provided on the outer edge of each of the separated ends, and a metal fitting having, for example, a spring property may be hung over the projection and fixed. That is, a protrusion is provided at the outer edge of each of the separated portions of the core material laminate at the time of manufacturing the iron core material, and after closing the core material laminate, the connecting tool is hung over the protrusion. The separated sites can be fixed to each other. The shape of the connecting tool in this case is not particularly limited.

Further, a laminate of the iron core material used in the above-mentioned manufacturing method is also novel. That is, according to the present invention, an iron core element used for manufacturing a rectangular cylindrical iron core for a transformer, which includes left and right legs and upper and lower yoke portions and has one square hollow portion. There, a plurality of core cores are laminated, and each core core separates the rectangular tubular core in the middle and cuts are provided at each corner of the hollow core side of the rectangular core. Thus, it is possible to provide an iron core element for a transformer, wherein the leg portion and the yoke portion are formed into a substantially linearly developed shape via the connecting portion.

Further, according to the present invention, the present invention is used to manufacture a rectangular prism-shaped core for a transformer, which comprises left, middle and right legs and upper and lower yoke portions and has two rectangular hollow portions. A core element formed by laminating a plurality of core elements, each core element forming a boundary between the above-described double-sided cylindrical core and the yoke on the upper or lower side of the central leg. Separated at the boundary between the part and the center leg of the lower or upper yoke part, and cuts are provided at each corner part on the hollow side of the double-sided cylindrical core to connect the leg part and the yoke part It is possible to provide an iron core element for a transformer, wherein the iron core element has a shape that is substantially linearly developed through the portion.

[0016]

According to the present invention, since the legs of the iron core developed linearly and the yoke are connected, it is ensured that the material lots are the same, and that the material lots It is no longer necessary to consider variations, and a high material yield can be secured.

Further, since the iron core is separated on the way and cuts are appropriately formed at the iron core corners on the hollow side and the iron core is developed linearly, the conductive wire and the nozzle of the winding machine interfere with the surrounding iron core. And the conductor can be wound directly around the legs of the iron core.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to specific examples shown in the drawings. FIG. 1 is a view showing a transformer manufactured in the first and second embodiments of the method according to the present invention, FIG. 2 is a view for explaining the above-described embodiment, and FIG. FIG. 4 is a view showing a transformer manufactured in the third and fourth embodiments of the method according to the present invention, FIG. 5 is a view for explaining the above-described embodiment, and FIG. FIGS. 7, 8 and 9 are diagrams showing three forms of fixing the separated end portion of the laminated body of the iron core material closed in each of the above embodiments. 10 to 13 are views for explaining a conventional method for manufacturing a transformer.

In FIG. 1, reference numeral 1 denotes an iron core constituted by a leg 2 and a yoke 3, and 5 denotes a winding constituted by a bobbin 6 and a conductor 7, and a transformer 10 is constituted as a whole.

In a conventional transformer, as shown in FIGS. 10A and 10B, two strip-shaped legs 2, 2 and a yoke 3 are fixed by means such as adhesion or the like to form a C-shaped transformer. The winding 5 is manufactured by winding the conductor 7 around the bobbin 6 in another step.
Is inserted into the legs 2 and 2 described above, and the yoke 3 serving as an upper lid is fixed between the other ends of the legs 2 and 2 so that the transformer 10 shown in FIGS. Had been completed.

The strip-shaped legs 2 and the yoke 3 are each formed by laminating a plurality of thin steel plates, but are separately managed because they are separated. In the assembling process, the leg 2 and the yoke 3 which are separately managed are randomly extracted, so that the fixed surfaces do not adhere to each other under the influence of the dimensional variation between lots, and a gap is formed. Cause deterioration of the mechanical characteristics.

FIG. 12A shows another conventional transformer.
An E core 4 having three legs 2... and a yoke 3 shown in FIG.
Each of the W-phases 5W was inserted, and the yoke 3 serving as the upper lid was fixed in the same manner as described above, thereby completing the transformer 10 shown in FIGS. 13A and 13B. However, as is evident from FIG. 12, the hollow portion 9 of the iron core 1 becomes a scrap for press working.
The material yield was low and the cost was high.

When the winding 5 is directly wound on the leg 2, a space for preventing the nozzle of the winding machine from interfering with the portion indicated by the symbol A in FIGS. 11 and 13 must be provided. There has been a problem that the winding space is reduced by that much and the so-called space factor of the winding is reduced.

FIGS. 1 to 9 show an embodiment in which the above-mentioned disadvantages are eliminated. FIG. 1A shows a primary winding 51 and a secondary winding 5.
2 of the first embodiment of the manufacturing method for individually winding
(b) is a second embodiment of the manufacturing method in which the primary winding 51 and the secondary winding 52 are stacked and wound, and the conductor 7 is wound directly around the leg 2 respectively.

FIGS. 2 (a) and 2 (b) show a state before assembling in which the iron core 1 according to the first and second embodiments is linearly developed, and a leg 5 is wound with a winding 5. FIG. By rotating the developed core element in the direction of the arrow in the figure around the center of the cross section, the conductor 7 is directly wound.

In this embodiment, the winding machine is provided with a guide plate (not shown), and the conductor 7 is shown in a completely straight wound form using, for example, a fusion electric wire. It can also be used by adding parts.

FIG. 3 shows the detailed structure of the iron core element used in the above embodiment. The iron core material is manufactured by laminating a plurality of iron core materials 11 and each iron core material 11 is manufactured using a thin steel plate. The iron core material 11 is obtained by separating the iron core 1 on the way. Cut the legs 2, 2 and the yoke 3, 3, 13.
.. are formed alternately, and between them are formed in a shape in which the upper edges are connected by connecting portions 14 having an arc shape. In the figure, reference numeral 12 denotes a separating unit for separating the iron core 1.

When the connecting portion 14 is bent such that the cuts 13 are in close contact with each other in the iron core member, the corners of the laminated body of the iron core members 11 are substantially at right angles. By appropriately selecting the shape, a chamfered shape or a rounded shape can be obtained.

FIGS. 4 to 6 show the third and fourth embodiments. FIG. 4A shows that two hollow portions 9 and 9 are provided in the iron core 1, and three legs 2, 2 and 2 respectively have three-phase windings 5 U, 5 V,
Third Embodiment of Manufacturing Method for Winding 5 W, FIG. 4B
Has two hollow portions, but a primary winding 5
A fourth embodiment of the manufacturing method of laminating and winding the primary and secondary windings 52 is shown.

FIGS. 5A and 5B show a state before assembling in which the iron core 1 in the third and fourth embodiments is linearly developed. In the third embodiment, the conductor 7 is wound around each of the three legs 2, 2, and 2 and the windings 5U, 5V, and 5W are wound. In the fourth embodiment, the conductor 7 is wound around the outer leg 2. Are wound in layers, and a primary winding 51 and a secondary winding 52 are wound.

FIG. 6 shows the detailed structure of the iron core element used in the above embodiment. The iron core member is manufactured by laminating a plurality of iron core members 11 also made of a thin steel plate. The iron core member 11 has three legs 2, 2, 2 and three yokes The portions 3, 3, 3 are formed alternately through cuts 13, and between them are formed in a shape in which the upper edges are connected by connecting portions 14 having an arc shape. Also, the center yoke 3 is set to a length obtained by adding the yoke portions 3 on both sides, and the separating portion 12 has the outer leg 2 at the center yoke 3 and the outer yoke 3 at the outer end. The iron portion 3 is formed in a shape rising up at a right angle so that the iron portion 3 can abut on the leg portion 2 at the outer end at a right angle.

FIGS. 7 to 9 show a method of closing and fixing the separation portions 12 of the iron core 1 in the first embodiment, but any method can be adopted. In FIG. 7, Y
Using a welding method such as an AG laser, a welding portion 15 is formed at the separation ends 12 and 12 and fixed.

In FIG. 8, holes 16 and 16 are formed in the vicinity of the separation ends 12 and 12 at the time of manufacturing the iron core material 11 or thereafter, and a clamp 17 is inserted into the holes 16 and 16. And fix it.

In FIG. 9, when manufacturing the iron core material 11,
Protrusions 18, 18 are formed on the separation ends 12, 12, and a metal fitting (connecting tool) 1 having spring properties when folded and closed after winding.
9 is fitted and fixed to the projections 18, 18.

[Brief description of the drawings]

FIG. 1 shows a first embodiment (a) of a manufacturing method according to the present invention.
FIG. 6 is a cross-sectional view showing a transformer manufactured according to the second embodiment (b).

FIG. 2 is a diagram for explaining the first and second embodiments (a) and (b).

FIG. 3 is a view showing an iron core member (laminated body of iron core members) (a) and an enlarged main part (b) thereof, which are substantially linearly developed in the embodiment.

FIG. 4 shows a third embodiment (a) of the manufacturing method according to the present invention.
FIG. 13 is a cross-sectional view showing a transformer manufactured according to the fourth embodiment (b).

FIG. 5 is a diagram for explaining the third and fourth embodiments (a) and (b).

FIG. 6 is a view showing an iron core member (laminated body of iron core members) (a) and an enlarged main part (b) thereof, which are substantially linearly developed in the embodiment.

FIG. 7 is a view showing a method (a) for fixing the separated end of the closed iron core element in the embodiment and details (b) thereof.

FIG. 8 is a view showing another fixing method (a) and details (b) of the separated end portion of the closed iron core element in the embodiment.

FIG. 9 is a view showing still another fixing method (a) and details (b) of the separated end portion of the closed iron core shaped member in the embodiment.

FIG. 10 is a view showing two examples (a) and (b) of manufacturing an iron core in a conventional manufacturing method.

FIG. 11 is a cross-sectional view showing transformers (a) and (b) manufactured by the above manufacturing method.

FIG. 12 shows still another example of the iron core in the conventional manufacturing method.
It is a figure which shows two manufactures (a) and (b).

FIG. 13 is a cross-sectional view showing transformers (a) and (b) manufactured by the above manufacturing method.

[Explanation of symbols]

1 iron core 2
Leg 3 Yoke 5 Winding 6
Bobbin 7 Conductor 8
Insulating paper 9 Hollow part 10 Transformer 11
Iron core material 12 Separated end 13
Notch 14 connecting part 15
Weld 16 hole 17
Clamp fittings 18 Projections 19
Spring bracket

Claims (9)

[Claims] 1. A transformer is formed by winding a winding around a leg of a rectangular cylindrical core having left and right legs and upper and lower yoke portions and having one square hollow portion. In doing so, the rectangular tubular core is separated in the middle and cuts are provided at each corner portion on the hollow side of the rectangular tubular core, and the legs and the yoke are substantially straightened through a connecting portion. Manufactured using a thin steel sheet iron core material of the shape developed in a shape, after laminating a plurality of the core material, and winding a winding around the leg of the laminated body of the core material, Manufacturing the transformer, wherein the laminated body of the core material is bent at each of the plurality of connecting portions to close the rectangular tube, and the separated portions are fixed to each other. Method. 2. A transformer formed by winding a winding around a leg portion of a double-sided cylindrical iron core having left and right middle legs and upper and lower yoke portions and having two square hollow portions. In manufacturing the vessel, the above-mentioned double-sided cylindrical core is separated at the boundary between the upper or lower yoke of the central leg and the central leg of the lower or upper yoke. Cuts are provided at the corners of the hollow portion of the double-sided cylindrical core at the hollow side, and the leg and the yoke are expanded substantially linearly through the connecting portion. After laminating a plurality of the core material and winding a winding around a leg of the laminated body of the iron material, the laminated body of the core material is subjected to each of the plurality of processes. A method for manufacturing a transformer, comprising forming the above-mentioned double-angled tubular shape by bending at a connecting portion, and fixing the separated portions to each other. . 3. The method for manufacturing a transformer according to claim 1, wherein the winding is wound by directly winding the conducting wire around the leg of the laminated body of the iron core material. 4. The winding of the conductive wire around the legs of the laminate of iron core members by rotating the substantially linear laminate of iron core members around the center of the cross section. The method for manufacturing a transformer according to claim 3, wherein 5. The method for manufacturing a transformer according to claim 1, wherein the separated portion of the closed laminated iron core material is fixed by welding. 6. A hole is formed at or after the production of the iron core material in the separated portions of the laminate of the iron core material, and after the laminate of the iron core material is closed, 3. The method for manufacturing a transformer according to claim 1, wherein the separated parts are fixed to each other by inserting a crimp-like connecting tool into the hole. 7. A projection is provided at an outer edge of each of the separated portions of the laminated body of the core material when the core material is manufactured.
3. The method for manufacturing a transformer according to claim 1, wherein after closing the laminated body of the iron core members, a connecting member is wrapped around the projection to fix the separated portions to each other. 8. An iron core element used for manufacturing a rectangular tubular iron core having left and right legs and upper and lower yoke parts and having one square hollow part, A plurality of core core members are laminated, each core core member separates the rectangular cylindrical core in the middle, and a cut is provided at each corner of the hollow core side of the square cylindrical core to form the leg. An iron core element for a transformer, wherein the core part and the yoke part have a substantially linearly developed shape via a connecting part. 9. An iron core element used for manufacturing a transformer core having a rectangular hollow shape, comprising a left middle right leg portion and upper and lower yoke portions and having two square hollow portions. A plurality of core cores are laminated, and each core core forms the above-mentioned double-sided cylindrical core at the boundary portion with the upper or lower yoke of the central leg and at the lower or upper side. Are separated at a boundary portion of the yoke portion with the central leg portion, and cuts are provided at respective corner portions on the hollow portion side of the double-ended cylindrical iron core to substantially connect the leg portion and the yoke portion via a connecting portion. An iron core element for a transformer, wherein the core element has a shape developed linearly.