JPH02214111A - Manufacture of wound iron core and apparatus therefor - Google Patents

Abstract

PURPOSE:To surely execute a breaking and cutting operation of a weak part without producing harmful broken pieces after a magnetic band has been wound by a method wherein a plurality of magnetic bands in which weak parts have been formed are piled up and wound. CONSTITUTION:Magnetic bands 40A to 40G are wound after weak parts 41A to 41G have been formed by the use of weak part forming mechanisms 36A to 36G at each prescribed position in a winding direction; after that, the weak parts 41A to 41G are broken and cut; a one-turn cut-type wound core is manufactured. During this process, a plurality of the magnetic bands 40A to 40G in which the weak parts 41A to 41G have been formed are piled up and wound. Since the plurality of the magnetic bands 40A to 40G are piled up and wound in this manner, a strength during their winding operation is enhanced as a whole; a sufficiently strong tension can be applied to the magnetic bands 40A to 40G during their winding operation; a swollen winding shape is not caused. Thereby, the weak parts 41A to 41G can be broken and cut surely without producing harmful broken pieces after their winding operation.

Description

[Detailed Description of the Invention] [Objective of the Invention J (Industrial Application Field) The present invention provides a method and apparatus for manufacturing a wound core in which a one-turn cut type wound core is manufactured by tearing a magnetic band after winding it up. Regarding.

(Prior art) Traditionally, the manufacturing of this square-wound iron core has been carried out using the
There is one shown in Japanese Patent No. 6088.

As shown in FIG. 6, a magnetic strip (generally a silicon steel strip) 1 is stepped at predetermined positions in the winding direction using an upper blade 2 and a lower blade 3 to form thin weak points 4. is formed and wound onto the winding shaft 5, and then removed from the winding shaft 5, formed into a rectangular shape, baked, and then the thickness of the roll is adjusted using a supporting mold 6 and a pressing mold 7 as shown in FIG. By applying pressure in this direction, the weak point portion 4 is torn and a one-turn cut type wound core is manufactured.

(Problems to be Solved by the Invention) In the case of the above-mentioned device, as shown in FIG. 8, the thickness of the magnetic band 1 is set to t. , if the film thickness of the weak point 4 is 1°, and the remaining thickness of the weak point [4 is t2, then at t2 1o-1°, the residual thickness t2 of the weak point 4 is the residual ratio α with respect to the entire thickness t0 of the magnetic band 1. is expressed by the following equation.

1 2 1. -1 α-X100 - X100
[%] jo t.

Here, in order to tear the weak point 4 under the pressure applied by the supporting die 6 and the pushing die 7, the survival rate α of the weak point 4 must be as small as possible, especially a value of 10% or less. Must be.

However, if the survival rate α of the weak point portion 4 is reduced in this way, the magnetic band 1 may be torn during winding, making winding impossible. Therefore, a sufficiently strong tension cannot be applied to the magnetic band 1 during winding. Then, in the wound state, as shown in FIG. 9, a gap 8 is created in each layer where the weak point 4 of the magnetic band 1 overlaps, and as a result,
The portion bulges outward to form a curly bulge 9.

As shown in FIG. 10, each time the winding bulge 9 passes through the winding roll 10 and guide roll 11, the weak point 4 is squeezed. A tear occurs at part 4.

FIG. 11 shows a state where the weak point 4 is torn in this way (cut 12), and when a break occurs in the magnetic band 1 in this way, there Slippage occurs, which not only makes it difficult to configure the joint position of the magnetic band 1 in the one-turn cut wound core, but also makes it impossible to continue winding the magnetic band 1.

Therefore, the survival rate α of the weak point 4 is actually 20[%]
We are trying to secure the above value.

However, if the survival rate α of the weak point part 4 is ensured to be large, as a matter of course, the clamping pressure by the above-mentioned support die 6 and push die 7 will not be able to reliably tear the weak point part 4,
In particular, if the weak point 4 is only deformed as shown in FIG.
Problems occurred from time to time that the material did not reach the point of tearing.

Therefore, as shown in FIG. 13, by inserting a pair of expansion molds 14 into the window portion 13 of the magnetic band 1 after forming and annealing, and driving a wedge 15 between the expansion molds 14, A method of applying tensile force to the weak point 4 to cause it to tear has been considered.

According to this method, the force applied to the weak point 4 is greater than the method using the above-mentioned clamping pressure using the supporting die 6 and the pushing die 7, and therefore the weak spot 4 can be torn more reliably than the method using the pinching pressure. However, with this method,
Although it is possible to cause the rupture, burrs 16 and fragments 17 are likely to be generated at the ruptured portion, as shown in FIG. The problem has been that the particles disperse and invade between the winding layers of the coil, becoming traps that cause dielectric breakdown.

The present invention has been made in view of the above-mentioned circumstances, and therefore, its purpose is to prevent the tearing of weak points after winding up a magnetic band.
The purpose of the present invention is to provide a method for manufacturing a wound core that can be carried out in a very convenient manner without producing harmful fragments, and which does not require any complicated means or structure to shift the necessary dimensions of the weak point part 11. To provide an apparatus for manufacturing a wound iron core that can be manufactured reliably without any unnecessary work.

[Structure of the Invention] (Means for Solving the Problems) The method for manufacturing a wound core of the present invention includes forming a weak point at each predetermined position in the winding direction and winding the magnetic band, and then forming a weak point at each predetermined position in the winding direction. The method for producing a one-turn cut wound core by tearing the magnetic strip is characterized in that a plurality of magnetic strips each having the weak point are superimposed and wound.

In this case, the above-mentioned wound core manufacturing apparatus includes a winding shaft, a drive mechanism that rotationally drives the winding shaft, and a plurality of weak points arranged annularly at equal distances from the winding shaft. It is preferable to include a forming mechanism and a magnetic band supply mechanism that supplies the magnetic band to the winding shaft through each of the weak point forming mechanisms.

(Function) According to the above means, since a plurality of magnetic strips are superimposed and wound, the overall strength during winding is increased. Therefore, during winding, it is possible to apply a sufficiently strong tension to the magnetic band, and it is possible to prevent the formation of bulges in the winding. Therefore, during winding, there is no possibility that some weak points will be torn due to ironing, and as a result, the survival rate of the weak points of the magnetic strip can be minimized to a value of 10% or less, for example. However, you can do it without any problem. In this way, with the weak point remaining as small as possible, the weak point can be determined after winding up without producing any harmful fragments.

On the other hand, in the configuration in which a plurality of magnetic strips are superimposed and wound as described above, the weak point forming mechanism is arranged in an annular manner at the same distance from the winding shaft, and the magnetic strip supplying mechanism is passed through each of the weak point forming mechanisms. If the magnetic strips are supplied to each of the winding shafts, the magnetic strips will be wound with their weak points shifted by a necessary predetermined dimension due to the difference in the winding diameters.

(Embodiment) An embodiment of the present invention will be described below with reference to FIGS. 1 to 5.

First, in FIG. 1, 21 is a winding shaft, and a winding roll 22 is provided in elastic pressure contact with the winding shaft from above. Reference numeral 23 denotes a first guide roll provided below the take-up roll 22 in elastic pressure contact with the take-up shaft 21, and reference numeral 24 indicates a second guide roll disposed below the first guide roll 23. , 25 is a third guide roll disposed below the second guide roll 24. other than this,
26 is a fourth guide roll, 27 is a fifth guide roll, 28 is a sixth guide roll, and 29 is a belt running amount measurement device arranged between the fifth guide roll 27 and the sixth guide roll 28. It is a device.

On the other hand, reference numeral 30 denotes an endless winding belt, which extends from the winding roll 22 portion to the entire outer periphery of the winding shaft 21, and extends from the winding roll 22 to the first guide roll 23. Second guide roll 24. Third guide roll 25. Fourth guide roll 26. The belt is provided so as to pass through the fifth guide roll 27 in order, pass through the belt running amount measuring device 29, further pass through the sixth guide roll 28, and return to the winding roll 22 portion.

Further, 31 is a motor, to which a driving sprocket 32 is attached, and a chain 34 is placed between the driving sprocket 32 and a driven sprocket 33 provided integrally with the second guide roll 24.

As a result, when the motor 31 is energized and started,
Rotational force is transmitted from the driving sprocket 32 to the driven sprocket 33 via the chain 34, and the second guide roll 24 is rotated in the counterclockwise direction shown by the arrow in the figure integrally with the driven sprocket 33. The winding belt 30 is pulled and runs to rotate the winding shaft 21 in the same counterclockwise direction, thus forming a drive mechanism 35 that rotationally drives the winding shaft 21.

36A to 36G are all weak point forming mechanisms, which are arranged in an annular manner at an equal distance from the winding shaft 21 (1), and each corresponds to a lower blade 37 which in this case exhibits a step downward from the front. On the other hand, 39A to 39G are uncoilers which are magnetic band supply mechanisms arranged on the side of the anti-winding pawl shafts 21 of the weak point forming mechanisms 36A to 36G, respectively. Each magnetic band (generally silicon steel band) 4OA to 40G
It is equipped in a wrapped state.

Now, in the case of the structure as described above, when manufacturing the wound core, first the uncoiler 39A or 3
The magnetic bands 40A to 40G are pulled out from each of the magnetic bands 9G, passed between the lower blade 37 and the upper blade 38 of the weak point forming mechanisms 36A to 36G, respectively, and further advanced in the direction of the winding shaft 21.

Next, place the tip of the magnetic band 40A on the winding shaft 21,
Place the tip of the magnetic band 40B on top of it.

In this case, the tip of the magnetic band 40B is shifted from the tip of the magnetic band 40A by a necessary predetermined dimension P (see FIG. 4).

Then, a magnetic band 40C is placed on top of the magnetic band 40B, a magnetic band 40D is placed on top of the magnetic band 40C, and a magnetic band 40E is placed on top of the magnetic band 40D. A necessary predetermined shift dimension P is secured for each. Then, after overlapping magnetic bands up to 40G, next the overlapping magnetic bands 40A to 40G
is press-fitted between the winding shaft 21 and the winding belt 30.

In this state, the weak point forming mechanism 36 or 36
G are activated all at once to form weak points 41 to 41G in the magnetic bands 40A to 40G as shown in FIG. 9 above.

After this, the motor 31 is energized to start it. Then, as described above, the winding belt 30 is pulled and runs, causing the winding shaft 21 to rotate counterclockwise. The press-fitted magnetic bands 40A to 40G are pulled in the same direction and wound around the winding shaft 21.

Here, the amount of one winding of the magnetic belt 40 or 40G (rotation amount of the winding shaft 21) is calculated by measuring the traveling distance of the winding belt 30 using the belt traveling distance measuring device 29. ,It is determined.

That is, it is necessary to form weak points 41A to 41G in the magnetic belt 40 to 40G at predetermined positions in the winding direction, and therefore, the belt running distance measurement device 29 measures the winding distance to the predetermined position. When the traveling distance of the entrainment belt 30 is calculated as 1Ilj, a signal is immediately issued, and the rotation of the motor 31 and the travel of the entrainment belt 30 (
This stops the rotation of the winding shaft 21. In particular, in the case of this embodiment, the predetermined position in the winding direction of the magnetic bands 40A to 40G refers to a position corresponding to one rotation of the winding shaft 21, and the distance the winding belt 30 travels to that point is measured, the winding belt 30 is moved by the motor 22 as described above.
The vehicle is stopped from running.

Next, when the running of the winding belt 30 is stopped as described above, at the same time, the weak point forming mechanism 36 or 36G
operate all at once again, forming weak points 41 to 41G in the magnetic bands 40A to 40G.

Further thereafter, the motor 31 starts to drive the winding belt 30 again in accordance with the upward return of each upper blade 38 in the weak point forming mechanisms 36A to 36G, and the magnetic belt 40 to 4
Resume 0G winding.

Here, regarding the formation of the weak points 41A to 41G, the respective windings of the weak point forming mechanisms 36A to 36G for forming the weak points 41A to 41G are discussed. Distance from th21! are set to be equal, and therefore, as shown in FIG. 3, the distances from the winding shaft 21 to the weak points 41A to 41G to be wound next are also equal at C. However, when winding a magnetic band of 4OA to 40G in such a situation, each layer has a different winding diameter, so the weak point 41
As shown in FIG. 4, the magnetic strips A to 41G are stair-stepped and are shifted by the dimension P for each magnetic strip of 40 to 40G.

The displacement dimension (displacement dimension) P is approximately 2t, π(
to: Thickness of one sheet of magnetic band 40A to 40G, π:
expressed as pi).

In addition, the shift dimension P is 40A to 40A due to magnetic characteristics.
The thickness of one sheet of G is t. It is sufficient that the shift dimension P expressed by 2toπ is several times as large as 2π of the 2toπ.
-It's about 6 times the size, so it's more than enough.

Thereafter, by repeating the above-mentioned operations, weak points 41^ to 41G are formed in the magnetic bands 40^ to 40G at predetermined positions in the winding direction, and while the weak parts 41^ to 41G are further shifted by a predetermined shift dimension P, The winding is completed as shown in FIG.

According to this embodiment as described above, the magnetic bands 40A to 4
Since 0G winds multiple sheets by overlapping them,
Overall, the strength during winding is increased. For this reason,
At the time of winding, a sufficiently strong tension can be applied to the magnetic bands 40A to 40G, and it is possible to avoid the formation of bulges as in the conventional case. Therefore, during winding, there is no possibility that some of the weak points 418 to 41G will be torn due to straining, and as a result, the weak points 41 to 41 of the magnetic bands 40^ to 40G will not be torn.
The residual rate α of G can be made as small as possible, for example, to a value of 10% or less. However, with levers such as this in which the survival rate of weak points is minimized, the tearing after forming and annealing of the weak points 41A to 41G after winding,
This can be done satisfactorily by the clamping force using the support die 6 and the push die 7 shown in FIG. After all, it can be carried out smoothly without producing any debris or the like.

This is also clear from FIG. 5, which was created based on the inventor's experimental results. In other words, when applying a tensile force of 4OA to 40G to the magnetic band to tear it, a tensile force of 15 to 20 [kg/square 2] is required for the survival rate of the weak points 41A to 41G aM30 [%]. However, the survival rate α of the weak points 41A to 41G
In the case of 10 [%], a tensile force of 3 [kg/mm2] was not required, and it could be easily torn and no fragments were produced.

Therefore, when installing the tenon into a transformer or the like in a subsequent process, there is no possibility that the fragments will be dispersed from the core and intrude between the winding layers of the coil, and the problem of insulation failure can be eliminated. .

In addition, in the case of the above, the magnetic band 40A to 40G
Since a plurality of sheets are overlapped and wound at once, the winding time can be reduced, and the process can be shortened.

Furthermore, since multiple types of materials are used for a single core, the characteristics of the core can be adjusted to average values that are not affected by the quality of the material properties, compared to the case where a single type of material was used. It is possible to obtain a wound core that can be made uniform and has uniform magnetic properties.

On the other hand, stack multiple magnetic strips of 40A to 40G.]
In the structure of winding the weak point forming mechanisms 36A to 36G in a ring shape at equal distances from the winding shaft 21, the uncoiler (magnetic band supply mechanism) 39A to 39A is passed through each of the weak point forming mechanisms 36A to 36G. In the configuration in which magnetic bands 40A to 40G are supplied from 39G to the winding shaft 21, respectively, the magnetic bands 40A to 40G are supplied to the winding shaft 21 as described above.
The necessary staggered displacement dimension P of the weak points 41A to 41G of A to 40G can be secured by using different winding diameters of each layer, without requiring any other complicated means or structure.
This has the effect that it can be carried out reliably.

In addition, the above-mentioned support die 6, push die 7, expansion die 14, and wedge 1
The tearing of the weak points 41A to 41G by No. 5 or the like may be performed not after annealing the wound core but before annealing. Further, the magnetic bands 40A to 40G may be made of a material other than silicon steel, such as an amorphous material.

Further, the numbers of these magnetic bands 40A to 40G, weak point forming mechanisms 36A to 36G, and uncoilers (magnetic band supply mechanisms) 39A to 39G may be larger or smaller than the above numbers.

[Effects of the Invention] The present invention is as described above, and has the following effects.

In the method for manufacturing a wound core according to claim 1, after forming a weak point at each predetermined position in the winding direction and winding the magnetic band, the weak point is torn, thereby producing a one-turn cut type wound core. In the manufacturing method, a plurality of magnetic strips with the weak point formed therein are superimposed and wound, so that the tearing of the weak point after winding up the magnetic strip can be prevented.
This process can be carried out very effectively without producing any harmful fragments, thereby preventing problems such as dielectric breakdown of built-in equipment such as transformers due to the fragments.

In the iron core manufacturing apparatus according to claim 2, for winding the magnetic strip as described above, a winding If shaft, a drive mechanism for rotationally driving this winding shaft, and a drive mechanism arranged at an equal distance from the winding shaft. The structure includes a plurality of weak point forming mechanisms arranged in an annular manner, and a magnetic band supply mechanism that supplies magnetic bands to the winding shaft through each of the weak point forming mechanisms. It is possible to reliably shift the required dimensions of the sections by changing the winding diameters of each layer without requiring any complicated means or structure.

[Brief explanation of the drawing]

Figures 1 to 5 show an embodiment of the present invention, in which Figure 1 is a longitudinal sectional front view of the entire winding device, and Figure 2 is an enlarged longitudinal sectional view of the magnetic band winding portion of the device. Figure 3 is an enlarged longitudinal sectional front view showing the relationship between the distance from the magnetic band winding part of the device to each weak point forming part of the magnetic band, and Figure 4 is a front view of the entire wound magnetic band. FIG. 5 is a diagram showing the relationship between the residual rate of weak points and tensile force. Also, Figures 6 to 14 show conventional devices, with Figure 6 being a partial longitudinal sectional front view of the winding device, and Figure 7 being a longitudinal sectional front view of the device for tearing the wound magnetic strip. 8 is an enlarged vertical sectional view of the weak point of the magnetic band, FIG. 9 is an enlarged longitudinal sectional front view of the winding portion of the weak point, and FIG. 10 is a longitudinal sectional front view of the weak point forming mechanism of the same part. Fig. 11 is a vertical cross-sectional front view of the part where tearing occurred at a weak point, Fig. 12 is an enlarged longitudinal cross-sectional view of the weak point where tearing failed, and Fig. 13 is a view of the wound magnetic strip. FIG. 14 is a longitudinal sectional front view of another tearing device, and is a partial plan view of the magnetic band after the weak point is torn by the same device. In the drawing, 21 is a winding shaft, 22 is a winding roll, 30 is a winding belt, 31 is a motor, 35 is a drive mechanism, 36A to 36G are weak point forming mechanisms 1, and 39A to 39G are uncoilers (magnetic strips). (supply mechanism), 40A to 40G are magnetic bands, and 41 to 41 are weak points.

Claims (2)

[Claims] 1. A method for manufacturing a one-turn cut wound core by forming a weak point at each predetermined position in the winding direction and winding the magnetic band, and then tearing the weak point, wherein the weak point is formed. A method for manufacturing a wound core, characterized in that a plurality of magnetic strips are superimposed and wound. 2. a take-up shaft; a drive mechanism that rotationally drives the take-up shaft;
A plurality of weak point forming mechanisms are arranged annularly at equal distances from the winding shaft, and a magnetic band supplying mechanism supplies a magnetic band to the winding shaft through each of the weak point forming mechanisms. A manufacturing device for wound iron cores.