JP2612305B2 - Manufacturing method of wound iron core - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing a wound iron core from an amorphous magnetic alloy ribbon.

[Prior art] Amorphous (amorphous) as a recently low-loss core material
Attention has been paid to magnetic alloys, and production of a power distribution transformer using an amorphous magnetic alloy is being studied.

2. Description of the Related Art Conventionally, as a core of a power distribution transformer using a silicon steel plate, a one-turn cut-type rectangular wound core is often used. This type of iron core has a structure in which a laminate of steel plates cut to have a length of one turn is formed into a rectangular shape, and a plurality of iron core blocks having both ends overlapped in a stepwise manner are further stacked. doing.

When manufacturing a one-turn cut iron core, a circular steel core formed by winding a steel strip is unwound and cut every turn, and the cut steel sheet is sequentially wound by shifting the position of the joint. It is formed to form a rectangular core. After annealing the wound iron core, the steel plates constituting the wound iron core are separated, and the steel plates of each turn are sequentially inserted into the windows of the winding wound in another process to assemble the transformer.

In the case where a wound core is formed from an amorphous magnetic alloy ribbon, the same method as described above has been studied. However, since the amorphous magnetic alloy ribbon has a thickness of only about 25 μm, it is very troublesome to handle, and it is inefficient to unwind a circular wound core and cut every turn.

Therefore, the present applicant has previously formed a plurality of laminated blocks corresponding to a plurality of expanded iron core blocks, respectively, and formed a plurality of laminated blocks in a circular winding one block at a time in order from the shorter one. A method of manufacturing a core in which a circular core is formed by winding the core between a core and a belt for driving the core and butt-joining both ends of each block, and then forming the circular core into a rectangular shape. Proposed.

[Problems to be Solved by the Invention] In order to take advantage of the excellent characteristics of the amorphous magnetic alloy and to facilitate the assembling work of the wound core, it is necessary to minimize the overlapping margin of the ribbon at the joint of each laminated block. It is necessary to make the gap as large as possible to minimize the gap generated at the joint.

Also, when assembling the transformer, after the core is annealed, the joint of the core is opened once, the core is inserted into the window of the coil and rejoined, but in this case, the overlap at the joint of the core is If it is too small, it will be difficult to perform the work of rejoining the iron core.

However, in the method proposed earlier, if the shape of the ribbon is not uniform, the unit laminates are displaced from each other due to the pressure of the belt, and both ends of the laminate block that has made one round are not accurately butt-joined. A gap was sometimes formed at the joint. If the gap at the joint becomes large, the flow of the normal magnetic flux is hindered, and the magnetic flux concentrates on the laminated block adjacent to the gap, thereby increasing the iron loss. It has become clear that the advantages of high quality magnetic alloys cannot be utilized.

In order to solve the above problem, it is desirable that both ends of the wound laminated block are overlapped in a stepwise manner and joined, and a method of winding the laminated block between a core and a belt is as follows. It is desirable not to take it. In this way, if a wound iron core is obtained in which both ends of each laminated block are correctly overlapped and joined, the magnetic flux flows smoothly through the overlapped joint and does not flow through the gap between the adjacent laminated blocks. The effect can be eliminated.

However, in the wound iron core to which the lap joint is applied, an extra lamination thickness of one unit lamination is required for each lamination block, and a plurality of lamination blocks having the same lamination thickness are sequentially arranged in ascending order of length. When the core block is formed by overlapping and winding on a rectangular core, the thickness of the joint becomes thicker as the outer core block becomes thinner, and the overlapping margin of the ribbon at the joint becomes smaller. There is a problem that the advantage of the joining cannot be utilized.

An object of the present invention is to provide a structure in which a plurality of unitary laminates of an amorphous magnetic alloy ribbon are laminated and a plurality of rectangular core blocks are further laminated in a state where both ends of each unit laminate are overlapped. In the method for manufacturing a rectangular core having the above-mentioned structure, it is an object of the present invention to enable the core to be manufactured while maintaining an overlapping margin at a joint of each core block to a predetermined size or more.

[Means for Solving the Problems] In the present invention, in order to achieve the above object, an amorphous magnetic alloy ribbon is cut in one direction in a laminating direction and developed by cutting the wound body. A step of forming a developed laminated body of a porous magnetic alloy ribbon, and dividing the developed laminated body, and laminating a predetermined number of amorphous magnetic alloy ribbons as the unit laminated body, each of the divided laminated bodies. A step of forming a plurality of laminate blocks each corresponding to a developed one of the plurality of iron core blocks by shifting the position of the unit laminate in the longitudinal direction for each, and shortening the length of the plurality of laminate blocks A step of superposing and winding one block at a time on a rectangular winding core and joining and bonding both ends of each block. Number of other laminates By making the number smaller than the number of unit laminates of the block, the overlap margin at the joint of each iron block is maintained at a predetermined size or more.

In order to make the number of unit laminates of a given laminate block smaller than the number of unit laminates of another laminate block when the plurality of laminate blocks are overlapped and wound, the plurality of laminate blocks are overlapped and wound. At this time, or before performing the step of stacking and winding a plurality of laminate blocks, a predetermined laminate block is removed from the predetermined laminate block in such a manner that the overlap margin of the unit laminate at the joint portion of each iron core block is kept to a specified size or more. The two unit laminates are removed.

In addition, by removing one unit laminate every time a predetermined number of laminate blocks are formed in the step of forming the laminate block, the overlap margin at the joint portion of each core block is maintained at a predetermined size or more. You may. In this case, each laminate block may be constituted by the same number of unit laminates,
Alternatively, the number of unit laminates of a laminate block formed after removing one unit laminate may be reduced by one from the number of unit laminates of a laminate block formed before that.

[Operation] As described above, when laminating the laminate block around the core, the number of unit laminates of the predetermined laminate block is reduced, or when the laminate block is formed, the predetermined number of unit laminates is reduced. When one unit laminate is removed each time a laminate block is formed, the overlap margin at the joint of each core block is prevented from decreasing, and the overlap margin at the joint of each laminate block is set to a predetermined size. Since the magnetic flux can be maintained more than the above, the flow of the magnetic flux at the joint portion of the iron core can be made good, and the characteristics of the wound iron core can be made good. In addition, since the overlap allowance at the joint portion of each laminate block can be increased, the work of assembling the iron core can be facilitated.

Embodiment An embodiment of the present invention will be described below with reference to the accompanying drawings.

1 to 6 show an embodiment of the present invention in the order of steps. In this embodiment, first, as shown in FIG. 1, an amorphous magnetic alloy ribbon 1 is wound around a winding core 2 having a circular cross section for a predetermined number of turns, and a circular winding body 3 having a predetermined thickness is formed. Form. In this case, a single amorphous magnetic alloy ribbon may be wound, or a polymer in which a plurality of amorphous magnetic alloy ribbons are stacked to facilitate handling may be wound.

Next, the winding core 2 is removed from the wound body 3 and a clamp 4 is attached to a part of the wound body 3 as shown in FIG. The clamp member 4 includes two clamp plates 5 and 6 for clamping the wound body 3 in the radial direction, and a bolt 7 and a nut 8 which are provided one by one and fasten the clamp plates in a direction to draw the clamp plates toward each other.
Consists of After clamping the wound body 3, a pair of bolts
The wound body 3 is collectively cut in the radial direction by a grindstone cutting machine or the like together with the clamp plates 5 and 6 at a portion located between 7 and 7. In FIG. 2, A indicates a cut surface.

After the wound body 3 is cut, one side of the clamp tool 4 cut in half and separated into two parts is removed, and the wound body 3 is developed as shown in FIG. The inclined laminated body 9 is formed.

Next, the remaining portion of the clamp 4 is removed, and the laminate 9 is divided into predetermined thicknesses to form a plurality of laminate blocks 9a, 9b,..., As shown in FIG. In the figure, one laminate block 9a is shown.) In each laminate block, a predetermined number of thin laminates are unit laminated.
By shifting the position of the unit laminated body 90 in the longitudinal direction as 90, the laminated surfaces 9a1 and 9a2 at both ends in the longitudinal direction of each laminated block are inclined stepwise. This operation is performed, for example, by disposing an inclined plate at one end in the longitudinal direction of the laminated block and shifting a thin strip constituting the laminated block so as to abut the inclined plate.

After the laminate blocks 9a, 9b,... Are formed as described above, these laminate blocks are sequentially superimposed while being formed along with a rectangular core 13 as shown in FIG. The both ends of the body block are overlapped and joined to form a rectangular wound core 15 as shown in FIG. Then, the core 15 is conveyed together with the core 13 into an annealing furnace while being constrained by the press form 14, and magnetically annealed to obtain a one-turn cut rectangular core 15. This rectangular wound core 15 has a structure in which the laminated body blocks 9a to 9e each form one turn, and the overlapping joint j at each end is located on one side of the core (in this embodiment, the upper yoke portion). Have.

FIG. 6 is an enlarged view showing the vicinity of the overlapping joint j of the laminated body blocks. At each joint, the thin strips of adjacent turns are overlapped with a predetermined overlapping margin d. When the second and subsequent laminated blocks 9b, 9c,... Are wound in layers, the thickness of the joint becomes thicker as the laminated blocks located on the outer side become thinner, so that the overlapping margin of the ribbon at the joint is small. Become. Therefore, in the case where the laminate blocks having the same thickness are wrapped around each other, the overlapping margin of the ribbon at the joining portion of the laminate blocks becomes smaller toward the outside. If the overlapping margin is smaller than the specified size, it becomes difficult to join the laminate blocks.

In the method of the present invention, in order to keep the overlapping margin of the ribbon at the junction of each laminated block to a specified size or more, one turn of the unit laminated body (1 step of the stepped inclined surface) is provided for each predetermined laminated block. The step of removing the strips (for the number of steps) is performed to reduce the number of steps (thickness of the stacked blocks) of the step-like stacked surface of the predetermined stacked block. This step may be performed in the step of forming the laminate block, or may be performed again after the step of forming the laminate block is completed. Further, when the laminated block is wound around the core, the unit laminated body may be removed from the predetermined laminated block based on the result of observing the state of the joint of each core block.

As described above, when a thin strip corresponding to one step (one unit laminate) of the stair-like inclined surface is removed by one turn from the intermediate laminate block to reduce the thickness of the laminate block, the outside of the block is removed. In the joint portion of the laminated block to be overlapped and wound, the overlapping margin of the ribbon can be returned to a predetermined size or more. Therefore, by reducing the thickness of the next laminated block when the overlapping margin is reduced to near the specified size, the overlapping margin of the ribbon at the joint of all the laminated blocks is more than the specified size. Can be kept.

In the above description, in the step of FIG. 1, a wound body having a thickness equal to the finished thickness of the wound iron core is wound once and cut, thereby forming one laminated body as shown in FIG. Although 9 is formed, the winding body may be divided into a plurality in the winding direction and wound in the step of FIG. For example, in the process shown in FIG. 1, a wound body having a thickness (T / 2) corresponding to a half of the finished thickness T of the wound iron core is formed with a thickness of T / 2 and a thickness of one unit laminated body. Are wound, two of which are different in diameter by an amount corresponding to the sum of the two, and are cut to form two laminates 9 having different lengths. You may divide | segment into a laminated body block, and you may make it remove the ribbon equivalent to one turn of a unit laminated body from a predetermined laminated body block. By adopting a method of winding a plurality of winding bodies having different diameters as described above, it is possible to reduce the number of laminated body blocks from which the ribbon is removed.

For example, when a wound body corresponding to the finished thickness T of the wound core is wound at one time to form one laminated body 9 having a thickness T, a thin strip is removed from three intermediate laminated body blocks. If it is necessary to perform two windings with different diameters in the process of FIG. 1 in the process of FIG.
One laminated block (two laminated blocks in total) among the laminated blocks formed by developing and dividing each wound body
Then, the ribbon may be removed.

In the above embodiment, the characteristics of the iron core become better as the thickness of the unit laminate 90 becomes thinner.However, when the thickness of the unit laminate is reduced, the number of lamination steps of the laminate block increases, and the man-hour for assembling the iron core and The man-hour for disassembling the core and inserting it into the coil increases.

The wound iron core manufactured as described above is inserted into a winding wound in another process. In this case, the core 13 is removed, and the other three sides excluding one side (upper yoke portion) having the joint j of the rectangular core 15 are covered with an insulating tape (for example, cotton tape) and restrained. Then, one side having the joint j is opened right and left at the joint, and the winding is fitted to the iron core.

One side that was opened after fitting the winding (upper yoke)
Is closed to form a joint j again, and the one side is covered and restricted by an appropriate means to complete the transformer.

In addition, as a method of keeping the overlap allowance of the joining portion of the laminated body block at a specified value or more, in the process of FIG. 1, when the winding body 3 is wound, the space factor is reduced from the actual space factor of the iron core. It is also conceivable that the thickness of the laminate blocks 9a, 9b,... Is sequentially changed so that the overlap margin at each joint of the laminate blocks 9a, 9b,. However, in such a case, the management of the thickness of each laminated block becomes very troublesome, and it is inevitable that the production efficiency is reduced.

In the above embodiment, the clamp plate constituting the clamp member 4 when the wound body 3 is cut in the process shown in FIG.
Although the cuts 4 and 5 are cut together, the wound body 3 may be cut between the divided portions of the clamp by using a clamp having a two-part structure.

In the above embodiment, the joints j of all the laminate blocks 9a, 9b,... Are located at one yoke, but the joints of the adjacent laminate blocks are alternately located at different yoke. You may do so.

In the above embodiment, in the step of forming the laminate block, by removing one unit laminate every time a predetermined number of unit laminates are formed, the overlap margin of the joint portion of each core block is set to a specified size. In the case where the number of unit laminates is kept at least, the number of unit laminates of the laminate block formed after removing one unit laminate is set to be smaller by one than the number of unit laminates of the laminate block formed before. However, in this case, all the laminate blocks may be formed by the same number of unit laminates.

For example, each laminated block is represented by n (n is an integer of 3 or more).
In the case of a configuration with a number of unit laminates, a predetermined number of laminate blocks composed of n unit laminates are formed,
One unit laminate is removed, and then a laminate block is formed from n unit laminates. This way,
Since the average length of the laminated body block formed after removing one unit laminated body can be made longer than the average length when the one unit laminated body is not removed, the overlapping of the core blocks The allowance can be returned to the initial size, and the overlap allowance at the joint of each iron core block can be kept to a specified size or more.

[Effects of the Invention] As described above, according to the present invention, in the step of forming a laminate block, one unit laminate is removed every time a predetermined number of laminate blocks are formed, or By reducing the number of unit laminates of a given laminate block when stacking and winding a plurality of laminate blocks, it was possible to prevent a reduction in the overlap allowance of each core block. The overlap margin at the joint can be maintained at a predetermined value or more, and the flow of the magnetic flux at the joint of the iron core can be improved to improve the characteristics of the wound iron core.

In addition, since the overlap allowance at the joint portion of each laminate block can be increased, there is an advantage that the assembling work of the iron core can be facilitated.

[Brief description of the drawings]

1 to 6 show an embodiment of the present invention.
FIG. 1 is a front view showing a step of forming a wound body by winding an amorphous magnetic alloy ribbon, FIG. 2 is a front view showing a step of clamping and cutting the wound body, and FIG. FIG. 4 is a front view showing a laminate formed by unrolling a wound body. FIG. 4 shows a state in which both end faces of one laminate block formed by dividing the laminate of FIG. 3 into a plurality of blocks are inclined. FIG. 5 is a front view showing a state in which the laminate block is sequentially wound around a rectangular core to form a rectangular core, and FIG. 6 is an enlarged cross-sectional view of the vicinity of a joint of the laminate block. It is. DESCRIPTION OF SYMBOLS 1 ... Amorphous magnetic alloy ribbon, 2 ... Circular core, 3 ... Wound body, 4 ... Clamping tool, 9 ... Laminated body, 9a-9e ... Laminated body block, 90 ... Unit Laminate, 13 …… Rectangular core,
15 …… Rectangular wound iron core.

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Takeshi Uchikura 2-1-1-11 Tagawa, Yodogawa-ku, Osaka-shi, Japan Daihen Co., Ltd. (72) Toshiko Yamada 2-1-1 Tagawa, Yodogawa-ku, Osaka-shi, Osaka No. Daihen Co., Ltd.

Claims (4)

(57) [Claims] 1. A structure in which a plurality of unitary laminates of an amorphous magnetic alloy ribbon are laminated and a plurality of rectangular iron core blocks are further laminated in a state where both ends of each unit laminate are overlapped. A method of manufacturing a rectangular wound iron core comprising: forming a rolled amorphous magnetic alloy ribbon by cutting and rolling a wound body of an amorphous magnetic alloy ribbon in one direction in a lamination direction; Dividing the spread laminate into a plurality of pieces, stacking a predetermined number of amorphous magnetic alloy ribbons as the unit laminate, and determining the position of the unit laminate for each of the divided laminates. Forming a plurality of laminate blocks each corresponding to a developed one of the plurality of iron core blocks by shifting in the longitudinal direction;
A step of lap-wrapping the blocks one by one on a rectangular core and joining and joining both ends of each block. When lap-wrapping the plurality of laminate blocks, the number of unit laminates of a predetermined laminate block is determined. A method for manufacturing a wound iron core, wherein an overlapping margin at a joint portion of each core block is maintained at a predetermined size or more by making the number of unit laminates of other laminated blocks smaller. 2. A structure in which a plurality of unitary laminates of an amorphous magnetic alloy ribbon are laminated and a plurality of rectangular iron core blocks are further laminated in a state where both ends of each unit laminate are overlapped. A method of manufacturing a rectangular wound iron core comprising: forming a rolled amorphous magnetic alloy ribbon by cutting and rolling a wound body of an amorphous magnetic alloy ribbon in one direction in a lamination direction; Dividing the spread laminate into a plurality of pieces, stacking a predetermined number of amorphous magnetic alloy ribbons as the unit laminate, and determining the position of the unit laminate for each of the divided laminates. Forming a plurality of laminate blocks each corresponding to a developed one of the plurality of iron core blocks by shifting in the longitudinal direction;
Forming a plurality of core blocks by overlapping and winding the blocks on a rectangular core and butt-connecting both ends of each block; and forming a predetermined number of laminates in the step of forming the laminate blocks. A method for manufacturing a wound iron core, comprising removing one unit laminated body every time a block is formed, thereby maintaining an overlap margin at a joint of each iron core block to a predetermined size or more. 3. The step of forming the laminate block,
The method according to claim 1, wherein each of the laminate blocks is constituted by the same number of unit laminates. 4. The step of forming the laminate block,
2. The method according to claim 1, wherein the number of unit laminates of the laminate block formed after removing one unit laminate is reduced by one from the number of unit laminates of the laminate block formed before. Or the method for manufacturing a wound iron core according to 2.