MXPA01001357A - Continuous winding process and apparatus for electrical transformer cores - Google Patents

Abstract

In an exemplary embodiment, the apparatus includes a first station, a second station, and a third station. At the first station, raw magnetic material strip (24) is de-reeled from a stock reel (42) and a predetermined amount of the raw magnetic material strip is fed and measured as the magnetic material strip is transported to a winding mechanism (60). In the winding mechanism, the magnetic material strip is continuously wound in and throughan opening formed in a bobbin (12, 14) to form a wound transformer core. Preferably, a pair of bobbins are used and the magnetic material strip is continuously wound through openings formed in each of the bobbins. After winding the predetermined amount of magnetic material strip through the bobbins, the magnetic material strip is cut at a predetermined measured location to produce a trailing edge (26) of material. At the second station (34), the trailing edge is secured to the underlying coils by a suitable process, e.g., plasma welding the trailing edge to the underlying coils. At the third station (36), the wound core of magnetic material is coined into a desired shape, such as a generally rectangular shape to form a wound electrical transformer.

Description

CONTINUOUS WINDING PROCESS AND APPLIANCE FOR ELECTRIC TRANSFORMER NUCLEI BACKGROUND OF THE INVENTION The present invention relates generally to electrical transformers, and more specifically, it relates to a process and apparatus for the continuous winding of a magnetic core strip in, and around, pre-wound reel winders. As is known, in the electronic industry, electrical transformers, for example, current transformers, are generally used in wide application arrangements, including the use of electrical transformers with printed circuit boards and with circuit interruption devices. The electric transformers are capable of supplying power to the circuit board, as well as sensing current in the primary circuit of the circuit board. In order for the electric transformer to provide adequate power to the circuit board, the transformer has a high magnetic permeability core and the transformer coil has a high number of cable turns to provide the required voltage. One of the most common transformers of the prior art is a toroidally wound transformer. An associated disadvantage of the toroidly wound transformer is that the manufacturing and winding process is very time consuming and is also .IM ^^ I, < ^ ^ lt. very expensive In recent years, the related electronics industry has begun winding coils around continuous lamination cores or closed magnetic cores of smaller transformers. Currently, most manufacturing processes of electrical transformers require the use of laminated magnetic materials to produce a core arrangement required for the application. The laminated core process has become a standard in the industry for electrical transformers used in circuit interruption devices, for example, switches, relays, etc., however, this process is intrinsically complicated, very laborious, and prone to failure . Therefore, all of the transformer winding processes mentioned above are very labor-intensive and very expensive processes. Accordingly, it may be desirable to have a generally less laborious automatic process for producing electrical transformers.

COMPENDIUM OF THE INVENTION The present invention is directed to a continuous core winding process and a winding apparatus used to produce electrical transformers. In its assembled state, the preferred electric transformer comprises a double-coil transformer having a first and a second winder. The electric transformer can also be in the form of a ^ S¡ || ^^^ ajjjj? s j ^^^ a single coil transformer having a first winder Each of the first and second winders has a cable turn arranged around a respective winder. An electrical connection is made between the cable turns to connect electrically with each other. Each of the winders includes a central opening in which a strip of magnetic material is continuously wound around to form a winding transformer core. In an exemplary embodiment, the apparatus includes a first station, a second station and a third station. In the first station, a strip of magnetic starting material is unwound from a reel of supply material and a predetermined amount of the strip of material. Magnetic starting material is fed as the strip of magnetic material is transported towards a winding mechanism. In the winding mechanism, the strip of magnetic material is continuously wound in and around the openings of each winder to form the winding transformer core. After winding the predetermined amount of strip of magnetic material through the winders, the strip of magnetic material is cut to a predetermined measured location to produce a trailing edge of material. In the second station, the trailing edge is secured to the underlying coils through a suitable process, for example, by plasma welding the trailing edge to the underlying coils. In the third station the winding core of I-a .í -Mite-rtfc.-alfeSfe, .... jtefea-AA. • Magnetic material is coined in a desired shape, such as a generally rectangular shape. The apparatus of the present invention is preferably controlled through a microprocessor, so that all the mechanical and electrical components of the apparatus are preferably integrated to achieve the product of optimum quality and achieve the optimum manufacturing cycle. The present process for winding the strip of magnetic material around the winders using the apparatus of the present invention provides a less time-consuming process as compared to the prior art. The aspects and advantages described above and others of the present invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Referring now to the drawings, in which similar elements are similarly enumerated in the different figures: Figure 1 is a front elevational view of an electric transformer formed in accordance with the process of the present invention; Figure 2 is a side elevational view of an illustrative apparatus for the continuous core winding of electric transformers in accordance with the present invention; Figure 3 is a side elevational view of a first station of the apparatus of Figure 2; Figure 4 is an enlarged view of a portion of the first station of Figure 3; Figure 5 is a perspective view of a winding surface for use in a winding device of the first station; Figure 6 is a side elevational view of a second station of the apparatus of Figure 2; and Figure 7 is a side elevational view of a third station of the apparatus of Figure 2 DETAILED DESCRIPTION OF THE INVENTION Referring to Figure 1, an illustrative electrical transformer produced in accordance with the process and apparatus of the present invention is generally indicated at 10. In this illustrative embodiment, the electrical transformer 10 comprises a double coil transformer, having a first winder 12 and a second winder 14. Arranged around each of the first and second winders 12 and 14 is a turn of cable (not shown), the use of which is known in the art.

An electrical connection is made between the cable Typically, this electrical connection is formed in at least one electrical cable 16 In the illustrated embodiment, each of the winders 12 and 14 has a pair of slots 18 formed therein. The slots 18 - * s¡aa¡ * mu * * ^ * * provide an access site for a pair of electrical cables 16 to run between the cable turns arranged around each of the winders 12 and 14. Each of the pair of cables 16 terminates in an electrical pin 17 which provides a means for electrically connecting the electrical transformer 10 to another device. As is known in the art, a winder having a turn of wire wrapped around and surrounding the winder is commonly referred to as a coil. Each of the winders 12 and 14 further includes a tongue 20 which extends outwardly from a side surface thereof. The tongue 20 is designed to centralize the transformer assembly with respect to machining. A central opening 22 is formed in each of the winders 12 and 14. In this embodiment, the central opening 22 generally has a rectangular shape; however, it is understood that the central opening 22 may have a variety of shapes. The electric transformer 10 includes a wound core of magnetic material 24, which, in the illustrated embodiment, is directed through central openings 22 of the first and second winders 12 and 14. The magnetic material 24 is preferably in the form of a strip of magnetic material, which is continuously wound around the first and second winders 12 and 14 through openings 22 to form a winding transformer core. After the magnetic material 24 is wound to a predetermined thickness around the first and second winders 12 and 14 respectively, this is cut at a predetermined location to form a trailing edge 26 of magnetic material 24. The trailing edge 26 is secured to the remaining portion of the magnetic material 24 by welding the trailing edge 26 to the wound portion Underlying the Magnetic Material 24 It is also within the scope of the present invention that the electrical transformer 10 may comprise a single winder 12 having an opening 22 formed therein, wherein the magnetic material 24 is wound around the opening 22 of the winder 12 individual. The electrical transformer 10 of Figure 1 can be used in a variety of environments and in an illustrative and preferred embodiment, the electrical transformer 10 is used in circuit interrupting devices, for example, circuit interruptions, relays and the like. The electric transformer 10 is particularly used as a device for sensing the current in these apparatuses. Referring to Figures 1 and 2-7 where an illustrative continuous winding process and apparatus for winding core of magnetic material 24 around one or more winders 12, 14 of the electric transformer 10 are illustrated. An illustrative apparatus 30 can be broadly considered as having a plurality of stations, wherein at least one specific task is performed at each station. For example, the apparatus 30 includes a first station 32 that includes a first ^^^ • - ^^^^^^ imifflfiflf 'stage, where a predetermined amount of starting magnetic material 24 is unwound, a second stage where the magnetic material 24 is fed and measured and a third stage where the material 24 is wound around one or more winders 12, 14, and a fourth stage wherein one end (trailing edge 26) of the magnetic material 24 is cut and held securely in place against the underlying coiled magnetic material 24. A second station 34 is provided to securely engage the trailing edge 26 to the wound portion underlying magnetic material 24, so that the magnetic material 24 is securely wrapped in and around one or more winders 12, 14. In a third station 36, the magnetic material 24 is preferably wedged in a desired and predetermined shape , such as a generally rectangular shape. It is understood that the various tasks previously described can be achieved in a different way among a plurality of stations or sections of the apparatus 30. The stations described above are presented for the purpose of illustration and do not limit the scope of the present invention. In other words, and for example, A separate station for cutting the magnetic material 24 can be designed in the apparatus 30, instead of having the cutting function incorporated in the first station 32. As shown, the components of the apparatus 30 are mounted to a support table 33. 25 Referring to Figures 1 and 3, the material t. ' ^--A ^ §- -. The magnetic material 24 is available in a variety of dimensions and, in particular, the magnetic material 24 is available in a range of widths and thicknesses. In order to manufacture the electric transformer 10, the number of coil turns of the magnetic material 24 (total amount of magnetic material 24) in and around the winders 12 and 14 depends on the thickness of the magnetic material 24 which is fed to the apparatus 30. Now, in describing the first and second steps of the first station 32, conventional feeding devices can be used to supply the magnetic material 24 to the apparatus 30. In an illustrative embodiment, the magnetic material 24 is supplied as a strip of magnetic material, arranged on a reel 40. A unwinding assembly, generally shown at 42, is provided to unseal the magnetic material 24 from the spool 40. The unwinding assembly 42 may be motorized or non-motorized, so that the magnetic material 24 is easily and appropriately fed to the apparatus 30. The motorized unwinding assembly 42 is driven through various means, including the use of a motor 47 which acts to unseal the magnetic material 24 of the spool 40. preferred embodiment further includes a servomotor 41 which acts to activate a pair of drive rollers 54 and 56, which act to drive the magnetic material 24 towards the first station 32. The servo motor 41 preferably includes an encoder 43, which allows an amount magnetic material default 24 be fed to the first station 32 of the apparatus 30. The encoder 43 measures the amount of material that is fed through the driving action of the servomotor 41. As is known in electric transformer technology, the amount of magnetic material 24 (surface area) of the laminate or in the case of the present invention, the continuous coil (core of magnetic material 24 wrapped) is related to the current output of the transformer. In this second step, the apparatus 30 provides the means to feed and accurately measure the correct amount of strip of magnetic material 24 that will be wound around the first and second winders 12 and 14. In an illustrative embodiment, approximately 279.4 cm of material 24 are fed to station 32 and wrapped in, and around, winders 12 and 14 disposed therein, as will be described in greater detail below. When it is determined that the desired amount of magnetic material 24 is to be fed to the first station 32, the encoder 43 will continuously measure the length of the magnetic material 24 that is fed, so that the appropriate amount of magnetic material 24 will be fed to it. the first station 24 can be easily determined. Alternatively, the length of magnetic material 24 that is fed can also be determined through a regular motor instead of a servo motor 41, wherein the regular motor includes a reducer for measuring the length of the material. Optionally, the apparatus 30 also includes a This is also an external encoder (not shown), which also measures the amount of magnetic material 24 that is fed to the first station 32 of the apparatus 30. It serves as a backup system for the encoder 43 included within of the servomotor 41, so that the desired and appropriate amount of magnetic material is fed to the first station 32. Other coding devices can be used in combination with the apparatus 30 of the present invention All the feeding and measuring systems work in conjunction with a PC or PLC base processor that provides the desired length of a particular electrical transformer 10 to the system Due to possible thickness variations (tolerance) of the strip of magnetic material 24, at least one thickness measuring device 59 constantly measures the thickness of the strip of magnetic material 24 before the magnetic material 24 reaches the thickness measuring device. or 59 and provide information to the system to interpolate the exact length needed in this thickness, to achieve the correct amount of magnetic material 24 in the electric transformer 10. The thickness measuring device 59 comprises a contact or non-contact device and, in an illustrative embodiment the thickness measuring device 59 comprises at least one roller, which acts to measure the thickness of the magnetic material 24 before the driving rollers 54 and 56. In another embodiment, the thickness measuring device 59 includes a metering pump thickness or a laser device. In addition, a reducer can be used to measure the thickness of magnetic material 24. It is also within the scope of the present invention that the thickness measuring device 59 can be located so that the device 59 measures the thickness of magnetic material 24 and either before or after the magnetic material 24 passes through the drive rollers 54 and 56. The system constantly updates the servomotor 41 as the amount of material is fed. This level of measurement ensures that no variation occurs in the present process due to deviations from the material. In an illustrative embodiment, the measurement of the strip of magnetic material 24 is preferably achieved by comparing the data of the servomotor 41 with the data provided by a reducer 61 mounted on the drive roller assembly. The correlation of this data provides the exact measurement of the strip of magnetic material 24 which is fed to a winder mechanism 60 (winding characteristic) of the apparatus 10. Again, the measurement of the strip of magnetic material 24 can be achieved through the interaction in the apparatus 10 of one or more devices acting by themselves or together with others. Some of the possible means of measurement include, but are not limited to, laser sensors, ultrasonic sensors, infrared sensors, encoders, etc. If the thickness of magnetic material 24 is at a low tolerance point of a predetermined weight tolerance scale, additional coil turns are needed in and around the First and second winders 12 and 14, so that the total thickness of the core of the magnetic material 24 is within the predetermined limits. Conversely, if the thickness of the magnetic material 24 is at a high tolerance point, the number of coil turns in and around the first and second winders 12 and 14 can be reduced. In this way, the unwinding operation allows a certain amount of magnetic material 24 to be released from the main material spool (reel 40) at all times, so that the feeding system of the present invention does not have to exert a force to actually pull the starting magnetic material 24 out of the spool 40, but only pull the strip of magnetic material 24 loose. This unwinding operation is achieved through the operation of the present process by the interaction of a switch that is activated when a strip of magnetic material 24 begins to become taut. In other words, the switch controls the on / off cycles of the motor 47 and when the switch is turned on and the motor 47 itself is in the on position, a non-tense portion of the magnetic material 24 is generated, so that the magnetic material 24 is loosely available to be directed towards the apparatus 30. In this manner, this switch allows the motor 47 of the unwinding assembly 42 to release the magnetic material 24 until the switch changes state again and the magnetic material 24 is not actively winding and in this way as the magnetic material 24 is directed towards ^^ gA ^^^^^ The apparatus 30, a voltage is created between the magnetic material 24 as it is pulled towards the apparatus 30. Once the voltage reaches a predetermined point, the switch changes the state again , and the magnetic material 24 is unwound from the spool 40 through the motor 47. Optionally, at least one roller 44 can be provided to direct the strip of magnetic material 24 from the spool 30 to a consumer port 46 of the apparatus 30. The consumer port 46 is preferably a slot in the apparatus 30, which is sized to receive the strip of magnetic material 24. Also, preferably provided near the consumer port 46 is a lubrication device (not shown), which disperses a small amount of lubricant on an upper surface of the strip of magnetic material 24 as the strip of magnetic material 24 is fed to the first station 32 and wound around the first and second winders 12 and 14. During the winding process, where the magnetic material 24 is continuously wound on the upper part thereof as it is wound on, and around the first and second winders 12 and 14, respectively, is developed certain amount of resistance (drag and friction). This resistance increases as the strip of magnetic material 24 is continuously wound. To reduce this level of strength and allow the strip of magnetic material 24 to be more easily fed to and through the first station 32, the lubricant is dispersed over mmaAmkuA? ^^^^^ - w its upper surface. This lubricant can be of many types, for example, an oil-based lubricant and even a soap-based mixture. Any number of conventional lubricating devices for applying the lubricant can be used and in an illustrative embodiment, an oiler throws oil into a cleaning mechanism, which in turn applies the oil to the upper surface of the strip of magnetic material 24 before it advance further to the first station 32, where the strip of magnetic material 24 is wound in the third stage. The lubricant can also be applied through spraying, dipping, brushing to name a few. Feeding the strip of magnetic material 24 to the apparatus 10, more specifically towards the winding mechanism 60, is preferably achieved through the pair of drive rollers 54 and 56 which compress on the strip of magnetic material 24 with an adjustable force and which rotate under the power of the servomotor. The drive rollers 54 and 56 are arranged after the magnetic material 24 is lubricated, but before it enters the winding mechanism 60. In the illustrative embodiment, the drive roller 54 is a fixed drive roller and the roller Drag 56 is a mobile drag roller. The force that is provided by the pair of drive rollers 54 and 56 can be generated in a variety of ways, either pneumatically, mechanically, electrically or through hydraulic means. A drag roller tensioner 57 can be used to adjust the force that is applied by the roller. drag 56. The rotational force for the drive rollers 54 and 56 can also be achieved by means other than the servomotor. For example, a successive-action motor, a standard motor, air power devices and the like can be used to generate the rotational force. Referring to Figures 1 and 3-5, the third stage of the first station 32 provides the area where the winding of the magnetic material 24 is presented. In the first and second winders 12 and 14 individually pre-wound with the main conductor (bar or cable 16) extending between them, they form a pre-winding winder assembly 31, which is manually or automatically placed in the winding mechanism 60 The positioning of the pre-wound winder assembly 31 can be achieved using a human operator, a robot or a hard automatic device. Once in place, the pre-wound winder assembly 31 will be the body that the magnetic material 24 will be wound around to form the electrical transformer 10. It is within the scope of the present invention that the winding mechanism 60 can be fixed to wind an individual winder or a double winder. When an individual winder (one of the first and second winders 12 and 14) is placed in the winding assembly 60, the first and second dice 62 and 64 are modified, so that the arcuate surfaces formed therein, cause the magnetic material 24 is wound through the opening 22 and ^ fc ^ g ^^^? É around the winder 12 or 14. As best shown in Figures 4 and 5, in the illustrative and presented embodiment, the winding mechanism 60 has a separation die design including a first given 62 and a second die 64. The first die 62 has a first guide lip 67 near a first end 66 extending downwardly from a lower surface 65 towards a second die 64. When the first and second die 62 and 64 are in in a close position a groove 69 is formed between the first die 62 and the second die 64. The groove 69 receives the strip of magnetic material 24, which travels with the groove 69 towards the first guide lip 67 during the feeding of magnetic material 24 in the winding mechanism 60. The second die 64 defines a cavity 70 formed therein, wherein in the illustrative embodiment, the cavity 70 generally has a circular shape. More specifically, the second die 64 has an upper portion 72 that includes a first surface 74 formed therein. Preferably, the first surface 74 is a first concave surface. The upper portion 72 further includes a first end 76, which is close to the first guide lip 67 when the first and second dice 62 and 64 are in the closed position. The cavity 70 is also defined by a second surface 78, which is formed in a lower portion 80 of the second die 64 and preferably is a second concave surface. A guiding shoulder 82 is formed in the portion The lower 80 on one end of the second concave surface 78 and a stepped shoulder 84 is formed in the lower portion 80 at an opposite end of the second concave surface 78, wherein this opposite end is in the stepped shoulder 84 which extends away from the second concave surface 78, and receives one of the winders 12 and 14. The second die 64 further includes a depression 86 formed therein adjacent the guide shoulder 82 to receive the other winders 12 and 14 In the upper portion 72, the first opposing concave surface 0 is a guiding surface 88. The guiding surface 88 faces the lower surface 65 of the first die 62 and partially defines the groove. In an illustrative embodiment, the strip of magnetic material 24 is directed through the guide surface 88 between the first and second dice 62 and 64 through at least one guide roller 89. In addition, guide legs 90 can be provided on the guide surface 88 to locate and properly guide the magnetic material 24 through the guide surface 88 toward the first guide lip 67 of the first die 62. As the strip of material magnetic 24 is fed through the surface of 0 guide 88, this continues in contour of the bottom surface 65 of the first die 62. Since the first guide lip 67 comprises an arcuate flex, this causes the magnetic material 24 to scale down towards the cavity 70 of the second die 64. Referring to Figures 1-5, the winding process of the present invention will be described in more detail below. continuation. The illustrative winding mechanism 60 shown in detail in Figures 4 and 5, is intended to receive and wind two winders, mainly an assembly of first and second pre-wound winders 31. The first winder 12 is preferably received in the cavity 70, so that one end of the first winder 12 sits against the stepped shoulder 84. The second winder 14 is disposed within the cavity 70, so that one end thereof is received in the depression 86, wherein a portion of the second winder 14 rests on the second guide lip 82. The second concave surface 78 includes a base surface 92 and an expansion surface 94, which in a retracted position rests on a base surface 92. The surface of Expansion 94 preferably has the same arcuate shape as the base surface 92, with the exception that an expansion surface width 94 is preferably apr. about half the width of the underlying base surface 92. Consequently, in the retracted position, half of the base surface 92 is covered by the expansion surface 94. The expansion surface 94 also includes a guide tab 98. , which acts to locate and guide the strip of magnetic material 24 downwardly from the guide surface 88 towards the expansion surface 94. As best shown in Figure 5, in the expanded position, the expansion surface 94 is disposed upward relative to the base surface 92. The expansion surface 94 is also preferably concave in nature, similar to the first and second concave surfaces 74 and 78, so that the strip of magnetic material 24 is wound around the pre-wound winder assembly 31 during the winding process of the present invention, as it will be described in more detail later. The movement of the expansion surface 94 through the actuator 100 causes the expansion surface 94 to move from the retracted position to the expanded position and vice versa, which can be achieved through known means. For example, in the illustrative embodiment, a pneumatically operated spring loaded retractor cylinder device 100 is used to apply a determined force to the expansion surface 94 to move the expansion surface 94 in a direction away from the base surface. 92 towards the expanded position. The expansion surface 94 is initially placed in a retracted position, so that the pre-wound winder assembly 31 can be inserted into the cavity 70. After inserting the pre-wound winder assembly 31 into the cavity 70 of the winding mechanism. winding 60, the expansion surface 94 moves toward the expanded position in a direction toward the first concave surface 74. When the expansion surface 94 is in the expanded position, the entire area of the cavity 70 is reduced, so that the The magnetic material strip 24 is wound more tightly around the pre-wound winder assembly 31, since the surface area at which the winding occurs is reduced. Further, the actuation of the expansion surface 94 will consequently cause the guide tab 98 to move in a direction away from the base surface 92 and this movement results in a gap 93, being formed between the guide tab 98. and a guide surface 88, wherein the strip of magnetic material 24 is fed through the gap 93 and around the arcuate surface (internal diameter) of the expansion surface 94. In other words, during the feeding and feeding operations. winding, the winding mechanism 60 provides the mechanical means for forcing the strip of magnetic material 24 in a linear motion along the guide surface 88, towards a circular winding action around the expansion surface 94, both in the retracted and extended positions. This change in direction is achieved by providing the leading edge of the strip of magnetic material 24 with a gradual change in direction and mechanically guiding this movement, so that the leading edge is directed by itself towards the central openings 22 of the first and second winders 12 and 14. Once the leading edge of the strip of magnetic material 24 reaches the winding mechanism 60, the first die 12 causes the strip of magnetic material 24 to meet the opening 22 in the first winder. 12, once beyond the first winder 12, the second die 14 provides the direction for the material to find the opening 22 in a given second 14. The arcuate nature of the expansion surface 94 in the retracted position against the second surface 14 directs the strip of magnetic material 24 towards and through the opening 22 in the second coil 14, and then the first surface 5 concave 74 of the upper portion 72 of the second die 14 directs the strip of magnetic material 24 towards the opening 22 in the first winder 12. Once the first revolution has been achieved within the winding mechanism 60 and through the openings 22 in the winders 12 and 14, the strip of magnetic material 24 will continuously be force fed by causing the leading edge to travel through the interior of the walls of the first and second winders 12 and 14, respectively, as the remainder of the strip of magnetic material 24 is wound on itself. Since the strip of magnetic material 24 is wound a In the predetermined number of revolutions around the first and second winders 12 and 14, the actuator 100 causes the expanded surface 94 to move from the retracted position to the expanded position, resulting in a smaller surface area for the strip of material magnetic 24 be wound around the first and second winders 12 and 14. In the first embodiment, the actuator 100 comprises a spring loaded pneumatic cylinder, which applies a predetermined amount of pressure to maintain the expanded surface 94 in the expanded position as the strip of material magnetic 24 is continuously wound. The force applied by the iiasáa ^ ^ pneumatic cylinder 100 l ^ adjustable so that by controlling the air pressure of the device 100, the generated resistance is controlled as well. Since the strip of magnetic material 24 is continuously being wound around the pre-wound coil assembly 31, the coil (strip of magnetic material 24) continuously increases in diameter. Due to the separation die design of the apparatus 10, the expansion surface 94 and the first arcuate surface 74 of the second die 14 are maintained on the same center line of the x-axis, but the expansion surface 94 can be moved on the axis z As the coil (strip of magnetic material 24) is wound and increases diameter. Accordingly, the center line of an internal diameter of expansion surface 94 is preferably centered to a strip center line of magnetic material 24, so that the winding process proceeds in a moderate and uniform manner. Accordingly, the expansion of the coil is taken by the force-loaded expansion surface 94 of the winding mechanism 60. In other words, as the diameter of the coil formed from the strip of magnetic material 24 increases, it is generated a force in a direction opposite to the force generated by the actuator 100. At the same point, this meeting force overcomes the adjustable force of the actuator 100 causing the expansion surface 94 to move in a direction toward the base surface 92 of the second given 64. The force applied by the actuator 100 can be varied for the application since it allows j | g¿i ^^^ gá ^ * ^ s "ááíjágtó ^ a resistance more or less to the strip of magnetic material 24 as it is wound inside the cavity 70, mainly the expansion surface 94 and the first concave surface 74 of the second die 14. These actions can easily be controlled by the processor, as is known in the art. In the fourth stage of the first station 32 and as best seen in Figure 4, once the predetermined and desired amount of the strip of magnetic material 24 is wound through the openings 22 of the first and second winders 12 and 14, a The cutting assembly 120 is driven to provide a cut at a predetermined site in order to maintain the correct length of the strip of magnetic material 24. As shown in Figure 4, preferably the cutting assembly 120 is designed in the first given 12 and the guide surface 88 (Figure 5) of the second die 14 of so that the strip of magnetic material 24 is cut in a cutting position along the length of the guide surface 88 near the first guide lip 67. The cutting assembly 120 comprises any suitable number of cutting devices. In the illustrative embodiment shown in Figure 4, the assembly of The cut 120 comprises an impact cylinder including a cutter head 122 at one end, which is directed downwardly to cut the strip of magnetic material 24 after the action of the cutter assembly 120. Preferably, the cutter assembly 120 is mechanically holds the strip of magnetic material 24 after that has been cut in order to avoid unraveling it, a or that the rear edge 26 (Figure 1) will not lose tension in it. This can be achieved using a variety of support mechanisms. Referring to Figures 3 and 6, the apparatus 30 5 preferably also includes a stopping gate device 91, which serves to locate the pre-wound winder assembly 31 within the winding mechanism 60. In the illustrative embodiment and presented , the stopping gate device 91 includes a stop gate 93, which, in a The first activated position extends upwards from a flat surface 95 adjacent the winding mechanism 60 and extending between the first station 32 and the second station 34, so that when the pre-unwind winder assembly 31 is placed in the winding mechanism. winding 60, this one is located within the first station 32 and access to the second station 34 is prevented. The stop gate device 91 may comprise any number of known stop devices, and in this mode, the stop gate device 91 comprises a cylinder tire, which after The actuation causes the stop gate 93 to go from a retracted position within an opening in the flat surface 95 to the first activated position shown in Figure 6. As shown in Figure 3, the link 97 is connected, in a end, to a first end the stopping gate device 91, and connects, at one end opposite the stop gate 93. From In this manner, the stop guide 93 is actuated to locate the pre-unwind winder assembly 31 in the direction and It should be understood that the stopping gate device 91 shown in FIGS. 3 and 6 is merely illustrative in nature and does not limit the scope of the present invention. Referring to Figures 2-5, the stop gate 93, which locates the pre-wound winder assembly 31 within the cavity 70 of the winding mechanism 60 during the winding process, is retracted, thereby allowing access to the second station 34. To transfer the pre-unwind winder assembly 31 having the strip of magnetic material 24 wound around it from the first station 32 to the second station 34, a conventional drive device 140 can be used. illustrative of the present invention, and as best shown in Figure 2, the driving device 140 includes a pneumatic cylinder 141, having a first extendible end 142, which contacts and physically moves the first and second winders. of winding 12 and 14 of the first station 32 to the second station 34 after actuation of the drive device 140. As is known, the device The drive device 140 preferably includes a microprocessor control, which allows the drive device 140 to be programmed, so that the first end 142 of the drive device 140 extends into and into the cavity 70, and directs the first and second second winding winders "t. ~ * 3L *, 12 and 14 away from the first station 32 and towards the second station 34. Accordingly, the first end 142 preferably has a circular shape and is complementary is shape with the cavity 70 to allow the first end 142 is received and directed therethrough Since the drive device 140 is programmed, the first and second winding winders 12 and 14 are directed only at a predetermined distance to properly locate the winders 12 and 14 within of a central portion of the second station 34. During this steering action, the trailing edge 26 of the strip of magnetic material 24 is held in place to prevent its unwinding After having located the first and second reels of the winding 12 and 14 inside the second station 34, the first end 142 is retracted out of the cavity 70, so that a second pre-unwind winder assembly 31 can be inserted into the cavity. ad 70 and the winding process can be started again. Furthermore, before inserting this second pre-winding winder assembly 31 into the cavity 70, the expansion surface 94 is likewise retracted. Figure 6 shows in more detail the second station 34, wherein the electric transformer 10 of Figure 1 is further manufactured. After the first and second winding winders 12 and 14 are transferred to the second station 34, the trailing edge 26 of the strip of magnetic material 24 is secure to the underlying coils. The trailing edge 26 is &; The taffle was held securely against the underlying coils through a tail clamp assembly 150. In an illustrative embodiment, the tail clamp assembly 150 comprises a pneumatic tail clamping cylinder, which applies a predetermined force. 5 to the trailing edge 26 in order to securely keep the trailing edge 26 against the underlying coils. Other retaining means may be used to securely keep the trailing edge 26 in place. Subsequently, the coils that form the strip of magnetic material 24 are secured to each other through any suitable process. In one embodiment, a predetermined site of the trailing edge 26 is welded to the underlying coils through a device 160 to form a coiled, secured assembly. An illustrative welding process is a welding process plasma, using argon gas in a plasma welder 160. It should be understood that other means of safety may be used, but including, but not limited to, laser welding, resistance welding, box welding, bonding, crimping or mechanical crimping. , calibrating the diameter of the coil and the use of wraps of cable. After the safety process is completed, the trailing edge 26 is secured to the underlying coils to form a hermetically wound coil. In the apparatus 10 of the present invention, the first and second winding winders 12 and 14 remain located inside the second station 34 after the trailing edge 26 2U * M k »*« * ± ^ -:? ^ ... ílf itii illiilÉiiil? M ^ ftÉfflMtlfifn has been insured. The tail-holding assembly 150 is retracted, so that the first and second winding winders 12 and 14 are free to be transferred to a third station 36 (Figure 7) In the present invention, the first and second winders 12 and 14 winding remain freely positioned within the second station 34 until another assembly of first and second winding winders of the first station 34 is directed towards the second station 36, thus displacing the assembly of first and second winding winders located in the second station 34. In this way, the driving drive of the winder assembly of the first station 32 forces the winder assembly in the second station 34 towards the third station 36. It is understood that it is within the scope of the present invention, that other drive mechanisms can be used to direct the winder assembly from the second station 34 to the third station 36. Referring to FIGS. 1 and 7, the third station 36 is illustrated in FIG. 7 and generally includes a process of coining embracing the formation or configuration of the winding coil of the magnetic material 24. The coil of winding of the magnetic material 24 is preferably coined or shaped to fix the coil to a geometry that conforms to the design of the product (electrical transformer 10) . In an illustrative embodiment, the third station 36 includes a first die of form 170 and a second die of form 172. The first die of form 170 is actuated by a first actuator 174, which in the present embodiment, comprises a first pneumatic cylinder which applies a force in a first direction towards an upper surface of the winding reel of the magnetic material 24. The second form die 172 is driven by a second actuator 178. Preferably, the second actuator 178 comprises a second pneumatic cylinder, which applies a force in a second direction to a bottom surface of the winding reel of the magnetic material 24. It should be understood that the first and second directions are generally opposite each other in order to compact or wedge the winding coil between the first and second dice of form 170 and 172 after the action of both. As is known, the coined shape of the electric transformer 10 can easily be varied by changing the shape of the first and second die shapes 170 and 172. Once the winding coil of magnetic material 24 has been coined to form the electric transformer 10. , the first and second dice of form 170 and 172 are retracted and the electric transformer 10 remains in place in the third station 36 until another winding coil assembly of the second station 34 is directed to a third station 36 resulting in the displacement of the electric transformer 10 of the third station 36. A conduit (not shown) can be provided by leading to a receptacle (not shown), which captures the electric transformers 10 as they are displaced from the third station 36 in a standstill. fully assembled It should be understood that a drive device (not shown) can be provided to mechanically transfer and move the electrical transformer 10 of the third station 36 after the first and second form dice 170 and 172 are retracted from each other. The apparatus 30 of the present invention and the process for forming the electric transformer 10 are preferably controlled by a microprocessor (not shown). All electrical and mechanical components of the apparatus 30 are integrated to achieve the best quality product that meets all predetermined specifications and achieves the most optimal manufacturing cycle. The present invention overcomes the deficiencies of the prior art by providing a fully integrated process and apparatus. , where all aspects of the assembly are verified and closely controlled. Although preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is understood that the present invention has been described by way of illustration and not limitation.

Claims (21)

1. A process for continually winding a magnetic material in, and through, openings formed in a pair of winders to form a wound core of an electrical transformer, comprising: inserting the pair of winders into a cavity formed in a winding fitting; feeding the magnetic material towards the winding fitting, so that the magnetic material is fed into a circular winding action, so that a leading edge of the magnetic material is continuously threaded into the openings formed in the pair of winders to form a core of winding transformer; cut the magnetic material to form a trailing edge; ensure that the trailing edge covers the winding transformer core material; and configuring the winding transformer core to a predetermined shape.

The process according to claim 1, wherein the winding attachment comprises a separation die assembly including a first die and a second die, a groove being formed between the first and second die receiving the customized magnetic material that it is fed to the winding attachment, the first and second dice, each one having a concave surface * f for directing the magnetic material through the openings of the first and second winders 3.

The process according to claim 1, wherein the feed comprises: feeding the magnetic material along a first arcuate surface of a first die, the first arcuate surface directing the magnetic material through the opening formed in the first winder, so that the magnetic material is fed along the first concave surface of the second die, which directs the magnetic material through the opening formed in the second winder, the magnetic material being continuously fed through the openings formed in the first and second winders to form a winding core.

The process according to claim 3, further comprising: feeding the magnetic material towards a second concave surface formed in the second die opposite the first concave surface, wherein the second concave surface directs the magnetic material towards the formed aperture in the second winder and directs the magnetic material towards the first opposite concave surface.

The process according to claim 1, wherein securing the trailing edge comprises: welding a predetermined location of the trailing edge to the underlying winding transformer core material.

The process according to claim 5, wherein the welding of the trailing edge comprises plasma welding.

The process according to claim 3, wherein the first concave surface is spring loaded, so that the magnetic material is initially fed into the winding fitting, when the first and second concave surfaces are in an expanded form , the first concave surface being forcibly moved in a direction away from the second concave surface as the magnetic material continuously winds around the first and second winders to adapt the magnetic material between the first and second concave surfaces

8. The process of according to claim 1, wherein the formation of the winding transformation core to the predetermined shape comprises: compressing a top surface of the winding transformer core with a first form die; and compressing a lower surface of the winding transformer core with a second form die.

9. A process for continuously winding a magnetic material in, and through, an aperture formed in at least one winder to form a winding core of an electric transformer, comprising: Insert a winder into a cavity formed in a winding attachment; feeding the magnetic material into the winding attachment, so that the magnetic material is fed towards a circular winding action, so that a leading edge of the magnetic material is continuously threaded into the opening formed in at least one winder to form a winding transformer core; cut the magnetic material to form a trailing edge; 0 securing the trailing edge to the underlying winding transformer core material; and configuring the winding transformer core to a predetermined shape.

10. An apparatus for continuously winding a transformer core in an electric transformer, having at least one winder, comprising: a winding attachment for continuously winding the magnetic material through an aperture formed in at least one winder , so that the magnetic material forms a plurality of winding coils arranged around at least one winder through the opening formed therein; a feed assembly for transporting the magnetic material to the winding accessory; a cutting device for cutting the magnetic material 5 at a predetermined point to form a trailing edge; a retraction device for securing the trailing edge to the underlying winding reels of the magnetic material to form a winding transformer core; and a wedging device for configuring the winding transformer core to a predetermined shape 11.

The apparatus according to claim 10, wherein at least one winder comprises a pair of winders.

The apparatus according to claim 10, wherein the winding attachment includes a first die and a second die, the first die including a first arcuate surface for directing the magnetic material towards the opening formed in a first winder, the second die. provided including a first concave surface for receiving the magnetic material from the first arcuate surface and directing the magnetic material towards the opening formed in a second winder.

The apparatus according to claim 12, wherein each of the first and second dice is spring loaded.

The apparatus according to claim 10, wherein the feed assembly comprises a pair of feed rollers, which forcibly transfer the magnetic material to the winding attachment, the pair of feed rollers being adjustable with respect to one to the other.

15. The apparatus according to claim 10, in This is where the retention device comprises a plasma welder

16. The apparatus according to claim 10, further including a measuring device for measuring a predetermined amount of magnetic material that will be wound around the pair of winders.

The apparatus according to claim 10, wherein the wedging device comprises a first form die and a second form die, the first form die compressing a first surface of the winding transformer core and the second die die. form compressing a second surface of the winding transformer core to the predetermined shape.

The apparatus according to claim 12, wherein the second die includes a second opposed concave surface facing the first concave surface to form a cavity that receives the pair of winders, the second concave surface for directing the magnetic material toward the opening formed in the first winder, the first concave surface can be moved between an extended position and a retracted position, wherein in the expanded position, the first concave surface is closer to the second concave surface than in the retracted position, the first concave surface directing the magnetic material towards the second concave material during the winding action.

19. The apparatus according to claim 18, wherein the movement of the concave prism is caused by an actuator. The apparatus according to claim 19, wherein the actuator comprises a pneumatic cylinder which when actuated moves the first concave surface toward the expanded position and applies a first force to the first concave surface to maintain the first concave surface in the expanded position, the first concave surface moving in a direction away from the second concave surface as the magnetic material is continuously rewound. The apparatus according to claim 12, wherein the first arcuate surface comprises an arched lip extending from the first die towards the second die, the arcuate lip being positioned that the magnetic material is directed through the opening of the first die. coil to the first concave surface of the second die. • jf-3 * '"* - ** -" "- In an illustrative embodiment, the apparatus includes a first station, a second station and a third station, in the first station, a strip of magnetic starting material (24) is unwound from a reel of supply material (42) and an amount The predetermined strip of the magnetic starting material is fed as the strip of magnetic material is conveyed to a winding mechanism (60). In the winding mechanism, the strip of magnetic material is continuously wound in, and through an opening formed in a winder (12, 14) to form a winding transformer core. Preferably, a pair of winders is used and the strip of magnetic material is continuously wound through openings formed in each of the winders. After winding the predetermined amount of the strip of magnetic material through the winders, the strip of magnetic material is cut at a predetermined measured location to produce a trailing edge (26) of material. In the second station (34), the trailing edge is secured to the underlying coils through a suitable process, for example, by plasma welding the trailing edge to the underlying coils. In the third station (36), the winding core of the magnetic material is coined to a desired shape, such as a generally rectangular shape to form an electric winding transformer. A • "-BnfhÍ --- i? F? Ti'-r" i-? Nffi?