Casting equipment and casting method for mutual inductor

Abstract

The present invention belongs to the technical field of mutual inductor manufacturing, and provides a casting device and a casting method for mutual inductors. The casting equipment includes: a casting tank and a mold that cooperate with each other; the casting tank includes a tank body, a casting platform, a conveying mechanism, an alignment mechanism and a feed arm arranged in the tank body; the mold includes a lower mold and an upper mold that cooperate with each other. The casting platform, the conveying mechanism and the alignment mechanism cooperate with the mold to achieve the fixation of the lower mold and the alignment and clamping of the lower mold and the upper mold. The stretchable injection tube in the feed arm cooperates with the upper mold to achieve automatic injection, cutting and feeding, and through the adjustment movement of the support of the casting platform simultaneously with the injection, and the multi-vacuum adjustment simultaneously with the feeding, rapid and thorough defoaming is achieved. The present invention has the advantages of high production efficiency, high automation rate, no overflow, no waste, no shortage of materials in the casting process, a flat bottom of the product after curing, and thorough defoaming to ensure stable quality.

Description

Technical Field

[0001] The present invention relates to the technical field of mutual inductor manufacturing, and in particular to a casting device and a casting method for a mutual inductor. Background Art

[0002] Instrument transformers are a common type of electrical equipment. Their fundamental principle is to convert high voltage to low voltage, or high current to low current, through electromagnetic induction. They are crucial for electrical isolation between secondary and primary equipment, electrical protection in conjunction with relays, instrument standardization, and centralized control.

[0003] Both current and voltage transformers are manufactured using a casting process. The existing casting process for transformer manufacturing is primarily based on a docking platform, a pouring tank, and a heating box. The process includes the following steps: first, the mold is placed on a tray on the docking platform; then, the tray is transferred via a conveyor rail to the pouring platform within the pouring tank, and the pouring port is aligned with the mold's pouring port for pouring; finally, after pouring is complete, the mold containing the castable is transferred via a conveyor rail via the docking platform to a heating box for primary curing.

[0004] However, the inventors discovered that the existing pouring process still has the following defects: First, the pouring port and pouring platform in the existing pouring tank are fixed, while the molds used to form different types of mutual inductors have different sizes, which makes it impossible to effectively align the injection port and the pouring port, especially when pouring mutual inductors with relatively small heights. This results in the castable being removed to the tray and the outer wall of the mold, which wastes raw materials and is difficult to clean. Secondly, manual feeding is required after a period of solidification to improve product quality. This process not only requires additional labor costs, but also the castable poured in the pouring tank has been solidified for a period of time, and the castable poured in the pouring tank after the entire product is solidified will be stratified due to inconsistent solidification time; or more serious quality problems such as material shortages may occur due to untimely feeding. Furthermore, when the buffer material inside the transformer coil reacts with the casting material, a vacuum degree of 300~500Pa is usually used for defoaming, but some bubbles still remain inside the coil, which makes it impossible to guarantee the local qualification rate of the transformer. Summary of the Invention

[0005] The object of the present invention is to provide a casting device and a casting method for a mutual inductor, so as to simultaneously solve the technical problems of overflow, material shortage, and inability to completely defoam in the prior art.

[0006] To achieve the above objectives, the present invention proposes the following technical solutions:

[0007] In the first aspect, the present technical solution provides a casting device for a mutual inductor. The device comprises: a casting tank and a mold that cooperate with each other; the casting tank comprises a tank body, a casting platform, a conveying mechanism, an alignment mechanism, and a feed arm arranged inside the tank body; the mold comprises a lower mold and an upper mold that cooperate with each other;

[0008] The tank body is a vacuum chamber with a vacuum degree range of 300Pa to 300000Pa. During the feeding process of the transformer to be cast and sealed, the tank body is subjected to multi-level vacuum degree control;

[0009] The pouring platform includes a carrier, a plurality of pillars and a first magnetic disk; the first magnetic disk is embedded in the carrier; one end of each pillar supports the carrier and the other end is fixed to the bottom of the tank, and each pillar has the freedom to independently adjust its height in a direction perpendicular to the bottom of the tank;

[0010] The transmission mechanism includes a first slide rail and a multi-axis clamp; the first slide rail is laid on the inner wall of the tank body, and the base of the multi-axis clamp is movably installed in the first slide rail;

[0011] A second magnetic disk is provided at the bottom of the lower mold, and the magnetic properties of the second magnetic disk are opposite to those of the first magnetic disk; a plurality of first alignment marks are etched on the top of the lower mold;

[0012] The upper mold includes a main body, a main pouring pipe, an auxiliary pouring pipe, a liquid level sensor, and a hanging piece; a plurality of second alignment marks are opened through the main body, and the shape and position of the second alignment marks correspond one-to-one with the first alignment marks; the main pouring pipe and the auxiliary pouring pipe are passed through the main body, and the liquid level sensor is installed inside the auxiliary pouring pipe; the hanging piece is arranged at intervals along the outer circumference of the main body and is movably clamped by the multi-axis clamping jaws;

[0013] The alignment mechanism includes a second slide rail, a camera, and a mounting member; the second slide rail is laid on the inner top wall of the tank body, one end of the mounting member is fixed to the camera, and the other end is movably mounted in the second slide rail;

[0014] The feed arm includes an injection pipe, which is a stretchable structure with freedom along its axial direction; the injection pipe is movably clamped and matched with the multi-axis clamping claws, and is movably plugged and matched with the main pouring pipe.

[0015] Furthermore, it includes a plurality of pressure sensors; the pressure sensors are all installed on the carrier, and the pressure sensors correspond to the pre-placement areas of the lower mold one by one.

[0016] Furthermore, it includes: the injection pipe includes a first magnetic ring, and the main pouring pipe includes a second magnetic ring; the first magnetic ring is sleeved on the spare end of the injection pipe, and the second magnetic ring is sleeved on the spare end of the main pouring pipe.

[0017] Furthermore, it includes: there are four pillars, which are arranged at the four corners of the platform; the pillars include a linear cylinder, a first fixing part and a second fixing part; the first fixing part is fixed to the base of the linear cylinder, and the second fixing part is fixed to the movable axis of the linear cylinder.

[0018] In a second aspect, the present technical solution provides a casting method for a mutual inductor, including:

[0019] When it is determined that the lower mold is located in a preset area of ​​the carrier in the casting platform, the first magnetic disk and the second magnetic disk are controlled to start magnetic attraction;

[0020] Obtain the model of the lower mold, use the multi-axis clamp based on the conveying mechanism to clamp the upper mold of the corresponding model, and superimpose it on the lower mold; at the same time, vacuum the tank body to 300~500Pa;

[0021] The alignment camera is called to take pictures of each alignment mark, and the upper and lower molds are judged to be complete when the overlap between the first alignment mark on the lower mold and the second alignment mark on the upper mold at the corresponding position is greater than a preset value;

[0022] When it is determined that the multi-axis gripper and the alignment camera are both placed in the initial positions, the multi-axis gripper is called again to grip the injection tube to insert it into the main pouring tube of the upper mold, and injection is started;

[0023] The injection is stopped when the injection height in the lower mold reaches a preset height, as determined by a liquid level sensor in the auxiliary pouring pipe of the upper mold.

[0024] Furthermore, the method includes: determining, based on a liquid level sensor in an auxiliary pouring pipe of the upper mold, that the injection height in the lower mold reaches a preset height before stopping the injection;

[0025] During the injection process, the pillars of the pouring platform are cyclically adjusted at a preset height and a preset frequency to periodically adjust the inclination angle of the mold according to a preset rule.

[0026] Furthermore, after stopping the injection when the injection height in the lower mold reaches a preset height based on the liquid level sensor in the auxiliary pouring pipe of the upper mold, the method includes:

[0027] After a preset period of rest, the injection pipe is opened to carry out the first feeding until the liquid level reaches a preset height after the first feeding, and then the feeding is stopped;

[0028] After the vacuum degree in the tank body is increased to 30000~50000Pa, the injection pipe is opened to carry out the second feeding until the liquid level reaches the preset height after the second feeding, and then the feeding is stopped;

[0029] After the vacuum degree in the tank body is increased to 100000~300000Pa, the injection pipe is opened to carry out the third feeding until the liquid level reaches the preset height after the third feeding, and the feeding is stopped;

[0030] During the first feeding, the second feeding and the third feeding processes, the pillars of the pouring platform are cyclically adjusted at a preset height and a preset frequency to periodically adjust the inclination angle of the mold according to a preset rule.

[0031] Furthermore, the method includes obtaining the tilt angle and adjustment period of the mold; including:

[0032] Acquire several sets of preferred adjustment data, wherein the preferred adjustment data include mold size, tilt angle, adjustment cycle and defoaming rate;

[0033] Iteratively training a machine learning regression model using the mold size and the defoaming rate as input until the difference between the output tilt angle and adjustment period and the actual tilt angle and adjustment period is less than an error threshold to obtain a target adjustment model;

[0034] The mold size corresponding to the mutual inductor to be injected and the expected defoaming rate are input into the target adjustment model to obtain the tilt angle and adjustment cycle used for actual adjustment.

[0035] Further, including:

[0036] When the model of the transformer to be cast is LZZBJ9-10, the tilt angle is 15 degrees, and the adjustment cycle is 5 seconds per time, for a total of 6 times. Beneficial effects

[0037] It can be seen from the above technical solutions that the technical solution of the present invention provides a casting device for a mutual inductor to improve various defects existing in the existing mutual inductor casting.

[0038] Based on the above embodiment, for the injection process of the mutual inductor, before injection, on the premise that the model of the mutual inductor to be cast is known, the multi-axis clamp will grab the upper mold of the corresponding model, and then the multi-axis clamp will grab the upper mold and move it to complete the mold closing with the lower mold with the assistance of the alignment mechanism. At this time, automatic mold closing is achieved through the transmission mechanism and the alignment mechanism. Compared with manual mold closing, on the one hand, it improves work efficiency, and on the other hand, it improves mold closing accuracy, avoids inaccurate alignment caused by manual mold closing, and thus avoids overflow during injection and feeding. During the injection process, since a liquid level sensor is provided in the auxiliary pouring pipe, during the injection and feeding process, the injection or feeding can be automatically stopped based on the limited height sensed by the liquid level sensor, thereby avoiding overflow caused by failure to close the material valve in time during manual control of the injection or feeding process. At the same time, since the injection tube is set as a stretchable structure, it is convenient to smoothly align the pouring port of the injection tube with the main pouring port of the main pouring pipe during the injection and replenishing process, and the alignment fit between the two in the existing technology can be converted into an insert fit, further avoiding overflow.

[0039] Because each of the pillars in the pouring platform allows for independent height adjustment perpendicular to the tank bottom, the pouring platform's carrier can be tilted during the filling and refilling processes to facilitate the movement of bubbles generated by the reaction between the buffer material and the pouring material to the liquid surface. This facilitates vacuum extraction, particularly multi-stage vacuum control during the refilling process, to effectively eliminate bubbles of all sizes. This prevents residual bubbles from impacting the local yield of the transformer. Furthermore, because the first magnetic disk in the carrier and the second magnetic disk in the lower mold have opposite magnetic properties, mold slippage and material overflow can be avoided during vacuum degassing.

[0040] The more thorough defoaming process during the refilling process improves the quality of the refilling process, thereby avoiding the occurrence of material shortages in the prepared mutual inductor. Furthermore, the tilted setting of the mold also facilitates refilling in various empty areas, further preventing material shortages.

[0041] It should be appreciated that all combinations of the foregoing concepts, as well as additional concepts described in greater detail below, to the extent such concepts are not mutually inconsistent, can be considered to be part of the inventive subject matter of this disclosure.

[0042] The foregoing and other aspects, embodiments, and features of the present invention will be more fully understood from the following description in conjunction with the accompanying drawings. Other additional aspects of the present invention, such as features and / or beneficial effects of the exemplary embodiments, will become apparent from the following description or through practice of specific embodiments according to the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component shown in various figures may be represented by the same reference numeral. For the sake of clarity, not every component is labeled in every figure. Embodiments of various aspects of the present invention will now be described by way of example and with reference to the accompanying drawings, in which:

[0044] Figure 1 This is a schematic structural diagram of the casting equipment for a mutual inductor according to this embodiment;

[0045] Figure 2 This is a flow chart of the casting method for a mutual inductor according to this embodiment;

[0046] Figure 3 This is a process flow chart for pre-drying the mold in this embodiment;

[0047] Figure 4 This is another flow chart of fixing the injection pipe and the main pouring pipe in this embodiment;

[0048] Figure 5 This is another specific injection flow chart of this embodiment;

[0049] Figure 6 Flowchart for feeding in this embodiment;

[0050] Figure 7 This is a flow chart for obtaining the tilt angle and adjustment cycle of the mold in this embodiment. DETAILED DESCRIPTION

[0051] To further clarify the objectives, technical solutions, and advantages of the embodiments of the present invention, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the described embodiments are only a portion of the embodiments of the present invention, not all of them. Based on the described embodiments of the present invention, all other embodiments derived by persons of ordinary skill in the art without requiring creative effort are within the scope of protection of the present invention. Unless otherwise defined, technical or scientific terms used herein shall have the ordinary meanings understood by persons of ordinary skill in the field to which the present invention pertains.

[0052] The terms "first," "second," and similar words used in the patent specification and claims of this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, unless the context clearly indicates otherwise, the singular forms of "a," "an," or "the" and similar words do not indicate a limitation of quantity, but rather indicate the presence of at least one. Terms such as "include" or "comprising" mean that the elements or objects preceding "include" or "comprising" encompass the features, integers, steps, operations, elements, and / or components listed after "include" or "comprising," and do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or combinations thereof. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0053] The existing technology still has the following defects when using the casting process to manufacture mutual inductors: First, the pouring port and pouring platform in the existing pouring tank are fixed, which makes it impossible to effectively align the injection port and the pouring port, resulting in a waste of raw materials and difficulty in cleaning. Secondly, after a period of curing, manual feeding operations are required to improve the surface quality of the product. Not only does this require additional labor costs, but after the entire product is cured, stratification occurs due to inconsistent curing time; or more serious quality problems such as material shortages occur due to untimely feeding. Furthermore, the local qualified rate of the mutual inductor cannot be guaranteed due to the residual bubbles inside the coil. At the same time, the existing pouring tanks are mostly single-unit casting, so there is also the problem of low production efficiency during actual production. Based on this, the present embodiment aims to provide a casting device for mutual inductors to simultaneously improve the above-mentioned technical defects.

[0054] The following is a detailed introduction to the casting equipment for mutual inductors disclosed in this embodiment with reference to the accompanying drawings.

[0055] like Figure 1 As shown, the pouring equipment includes a pouring tank 1 and a mold 2 that cooperate with each other. The pouring process of the transformer is mainly completed by injecting material into the mold 2 within the pouring tank 1. Specifically, the pouring tank 1 includes a tank body 11, and a pouring platform 12, a conveying mechanism, an alignment mechanism, and a feed arm 13 disposed within the tank body 11. The mold 2 includes a lower mold 21 and an upper mold 22. The mold 2 corresponds to the model of the transformer to be cast. The lower mold 21 and the upper mold 22 must be closed and matched before pouring.

[0056] Regarding the specific structure of the pouring tank 1, the mutual inductor pouring process includes filling and refilling. The entire pouring process is performed in a vacuum environment. Therefore, the tank body 11 is specifically a vacuum chamber with a vacuum level range of 300 Pa to 300,000 Pa. During the actual refilling process, the tank body 11 is subjected to multi-level vacuum control.

[0057] The pouring platform 12, used to support the mold 2 during the entire pouring process, comprises a carrier 12a, several supports 12b, and a first magnetic disk. Specifically, the first magnetic disk is embedded within the carrier 12a. Each support 12b supports the carrier 12a at one end and is secured to the bottom of the tank 11 at the other end. Each support is independently adjustable in height perpendicular to the tank bottom. In this embodiment, there are four supports 12b, located at the four corners of the carrier 12a. Each support 12b comprises a linear cylinder, a first fixing member, and a second fixing member. The first fixing member is secured to the base of the linear cylinder, and the second fixing member is secured to the movable axis of the linear cylinder.

[0058] The conveying mechanism includes a first slide rail and a multi-axis gripper. The first slide rail is laid on the inner wall of the tank 11, and the base of the multi-axis gripper is movably mounted within the first slide rail. Because the multi-axis gripper operates in a vacuum environment, it is specifically a multi-axis gripper based on the principle of friction.

[0059] The alignment mechanism includes a second slide rail, a camera and a mounting member; the second slide rail is laid on the inner top wall of the tank body 11, one end of the mounting member is fixed to the camera, and the other end is movably installed in the second slide rail.

[0060] The feed arm 13 includes a filling tube 13a, a stretchable structure with axial freedom. The filling tube 13a is movably clamped by the multi-axis gripper and movably plugged into the main pouring tube 22b in the upper mold 22. In this embodiment, multiple filling tubes 13a are provided, and the mold-holding platform 12a that supports them can also accommodate multiple molds simultaneously. This allows for the simultaneous casting of multiple transformers of different models, significantly improving production efficiency compared to existing pouring tanks that can only cast one transformer at a time.

[0061] Regarding the specific structure of the lower mold 21: a second magnetic disk is provided at the bottom thereof, and the second magnetic disk has opposite magnetic properties to the first magnetic disk in the upper platform 12a of the casting platform 12. A plurality of first alignment marks are etched on the top of the lower mold 21.

[0062] Regarding the specific structure of the upper mold 22: the upper mold 22 includes a main body 22a, a main pouring pipe 22b, an auxiliary pouring pipe 22c, a liquid level sensor and a hanging piece. Among them, the main pouring pipe 22b is used for injection or replenishment, and the auxiliary pouring pipe 22c is used for exhaust. A number of second alignment marks are opened through the main body 22a, and the shape and position of the second alignment marks correspond one-to-one to the first alignment marks on the lower mold 21. The main pouring pipe 22b and the auxiliary pouring pipe 22c are passed through the main body 22a, and the liquid level sensor is installed inside the auxiliary pouring pipe 22c; the hanging piece is arranged at intervals along the outer circumference of the main body 22a, and cooperates with the multi-axis clamp to movably clamp.

[0063] At this time, for the injection process of the mutual inductor, before injection, on the premise that the model of the mutual inductor to be cast is known, the upper mold 22 of the corresponding model is grasped based on the multi-axis clamp, and then the multi-axis clamp grasps the upper mold 22 and moves it to complete the mold closing with the lower mold 21 with the assistance of the alignment mechanism. At this time, automatic mold closing is achieved through the transmission mechanism and the alignment mechanism. Compared with manual mold closing, on the one hand, it improves work efficiency, and on the other hand, it improves mold closing accuracy, avoids inaccurate alignment caused by manual mold closing, and thus avoids overflow during injection and feeding. During the injection process, since a liquid level sensor is set in the auxiliary pouring pipe 22c, during the injection and feeding process, the injection or feeding can be automatically stopped based on the limited height sensed by the liquid level sensor, thereby avoiding overflow caused by failure to close the material valve in time during manual control of the injection or feeding process. At the same time, since the injection tube 13a is set as a stretchable structure, it is also convenient to smoothly align the pouring port of the injection tube 13a with the main gate of the main pouring pipe 22b during the injection and replenishment process, and the alignment fit between the two in the existing technology can be converted into an insert fit, further avoiding overflow.

[0064] Because each of the support columns 12b in the pouring platform 12 is independently height-adjustable perpendicular to the tank bottom, during the filling and refilling processes, the support columns 12b can be used to tilt the platform 12a to facilitate the movement of bubbles generated by the reaction between the buffer material and the pouring material to the liquid surface. This is combined with vacuum pumping, particularly multi-stage vacuum control during the refilling process, to effectively eliminate bubbles of all sizes. This prevents residual bubbles from impacting the local yield of the transformer. In practice, the vacuum level during the filling process is controlled to be 300-500 Pa; the vacuum level during the refilling process is controlled to be 300-500 Pa, 30,000-50,000 Pa, and 100,000-300,000 Pa, respectively. Specifically, the vacuum level during the filling process is controlled to be 300 Pa; the vacuum level during the refilling process is controlled to be 300 Pa, 50,000 Pa, and 100,000 Pa, respectively. At the same time, since the magnetic properties of the first magnetic disk in the carrier 12a and the second magnetic disk in the lower mold 21 are opposite, overflow caused by mold sliding can be avoided during vacuum tilt defoaming.

[0065] The more thorough defoaming process during the refilling process improves the quality of the refilling process, thereby avoiding the occurrence of material shortages in the prepared mutual inductor. Furthermore, the tilted setting of the mold also facilitates refilling in various empty areas, further preventing material shortages.

[0066] As another specific embodiment, the area corresponding to the first alignment mark in the upper mold 22 is inlaid with a transparent block in a one-to-one correspondence, and the second alignment mark is etched on the transparent block. The alignment mechanism can use a camera for alignment or a laser for alignment. In this case, a laser alignment instrument is loaded on the mounting member. The shapes of the first alignment mark and the second alignment mark can be a triangle, a cross or a pentagon. In order to improve the alignment efficiency, during the alignment process, only a pair of alignment marks located at diagonal positions are confirmed by the alignment mechanism to achieve alignment.

[0067] To facilitate transport of the lower mold, the pouring tank 1 also includes a tray 14. The tray 14 is used to hold the lower mold 21. In another specific embodiment, to prevent the tray 14 or the lower mold 21 thereon from sliding off when the pouring platform 12 tilts, a third magnetic disk is embedded within the tray 14. The magnetic properties of the third magnetic disk are opposite to those of both the first and second magnetic disks; in this case, the magnetic properties of the first and second magnetic disks are the same.

[0068] To further automate the entire pouring process and improve efficiency, the pouring tank 1 is configured to include several pressure sensors. Each of these pressure sensors is mounted on the carrier 12a, corresponding one-to-one with the pre-placement area of ​​the lower mold 21. The pressure sensors automatically monitor the placement of the lower mold 21, eliminating manual intervention. As a preferred embodiment, the pressure sensors can also be used in conjunction with the liquid level sensor during the pouring process to accurately cut the material, further preventing overflow.

[0069] As a preferred embodiment, in order to prevent the injection tube 13a from slipping out of the main pouring pipe 22b during the injection process, the injection tube 13a is provided with a first magnetic ring, and the main pouring pipe 22b is provided with a second magnetic ring; the first magnetic ring is provided on the free end of the injection tube 13a, and the second magnetic ring is provided on the free end of the main pouring pipe 22b.

[0070] This embodiment also provides a casting method for a mutual inductor, and the casting method is performed based on the casting equipment.

[0071] The following is a detailed introduction to the transformer casting method described in this embodiment with reference to the accompanying drawings.

[0072] like Figure 2 As shown, the casting method includes:

[0073] Step S202 : When it is determined that the lower mold is located in the preset area of ​​the carrier in the casting platform, the first magnetic disk and the second magnetic disk are controlled to start magnetic attraction.

[0074] In this step, it is determined whether the lower mold has reached the preset area based on the pressure sensor provided on the carrier.

[0075] In specific implementation, Figure 3 As shown, before step S202, the lower mold is dried by the following operations:

[0076] Step S201: Place the lower mold with the coil in a drying oven for drying, and then transfer it to a preset area on the carrier based on a chain track.

[0077] Step S204: Obtain the model of the lower mold, use the multi-axis clamp based on the conveying mechanism to clamp the upper mold of the corresponding model, and stack it on the lower mold; at the same time, vacuum the tank body to 300~500Pa.

[0078] Step S206: call the alignment camera to take pictures of each alignment mark, and determine that the upper and lower molds are closed when the overlap between the first alignment mark on the lower mold and the second alignment mark on the upper mold at the corresponding position is greater than a preset value.

[0079] At this point, steps S204 through S206 complete the precise closing of the upper and lower molds, thereby preventing overflow during subsequent injection or refilling. In practice, the degree of overlap corresponds to a specific alignment score: a zero overlap corresponds to a zero score; a 100% overlap corresponds to a 10 score. In this embodiment, the preset value for the alignment score is 9.

[0080] The specific alignment process is as follows: first, align the geometric centers of the first and second alignment marks, then adjust them so that their geometric edges coincide. To improve alignment efficiency, only the two pairs of alignment marks at opposite corners can be aligned. In this case, the preset alignment score can be increased to ensure alignment accuracy.

[0081] Step S208: When it is determined that the multi-axis gripper and the alignment camera are both placed in the initial positions, the multi-axis gripper is called again to grip the injection tube to insert it into the main pouring tube of the upper mold, and injection is started.

[0082] This embodiment enables the multi-axis clamp to maintain the insertion action of the injection tube during the entire injection process to prevent it from slipping out of the main pouring tube during the injection process.

[0083] As another specific embodiment, if the injection tube and the main pouring pipe are equipped with a magnetic device, the magnetic device can be turned on after the multi-axis clamping jaws clamp the injection tube and insert it into the main pouring pipe of the upper mold to ensure the stability of the connection between the two. Figure 4 As shown, the step S208 may be:

[0084] Step S208.2': when it is determined that the multi-axis gripper and the alignment camera are both placed in the initial positions, the multi-axis gripper is called again to grip the injection tube to insert it into the main pouring tube of the upper mold.

[0085] Step S208.4': after determining that the injection pipe and the main pouring pipe are magnetically attracted, place the multi-axis clamp in the initial position and start injecting.

[0086] Step S210: Stop filling when the injection height in the lower mold reaches a preset height based on the liquid level sensor in the auxiliary pouring pipe of the upper mold.

[0087] In order to further avoid overflow, the pressure sensor can simultaneously determine that the injection weight in the lower mold reaches a preset weight to stop injection.

[0088] In order to effectively defoam during the injection process, Figure 5 As shown, before step S210, the following steps are also included:

[0089] Step S209: During the injection process, the pillars of the pouring platform are cyclically adjusted at a preset height and a preset frequency to periodically adjust the tilt angle of the mold according to a preset rule.

[0090] Since injection is a dynamic process, the generation of bubbles between the cushioning material and the casting material is also a dynamic process. Therefore, in a vacuum environment, combined with the cyclic tilting of the mold, newly generated bubbles are quickly brought to the liquid surface and eliminated promptly, preventing them from remaining in the mold.

[0091] like Figure 6 As shown, after the injection is completed, continue to refill the material through the following steps:

[0092] Step S212: After being still for a preset period of time, the injection pipe is opened to perform the first feeding until the liquid level reaches a preset height after the first feeding, and then the feeding is stopped.

[0093] Step S214: After the vacuum degree in the tank body is increased to 30,000-50,000 Pa, the injection pipe is opened to carry out a second feeding until the liquid level reaches a preset height after the second feeding, and the feeding is stopped.

[0094] Step S216: After the vacuum degree in the tank body is increased to 100,000-300,000 Pa, the injection pipe is opened to perform the third feeding until the liquid level reaches a preset height after the third feeding, and the feeding is stopped.

[0095] During the first feeding, the second feeding and the third feeding processes, the pillars of the pouring platform are cyclically adjusted at a preset height and a preset frequency to periodically adjust the inclination angle of the mold according to a preset rule.

[0096] As can be seen, in this embodiment, injection and refilling are continuous operations performed within the tank. That is, curing occurs only after refilling is complete, thereby avoiding stratification caused by inconsistent curing times. Furthermore, the refilling process utilizes multi-stage vacuum control coupled with cyclic angle adjustment, facilitating rapid and thorough defoaming while also improving refilling quality.

[0097] After step S216 is completed, the mold is placed in a drying oven for curing. In this embodiment, the vacuum degree of the first filling is specifically 300 Pa, the vacuum degree of the second filling is specifically 50000 Pa, and the vacuum degree of the third filling is specifically 100000 Pa.

[0098] In order to obtain the tilt angle and adjustment period of the mold in order to avoid repeated experimental operations, Figure 7 As shown, the following process is also included:

[0099] Step S402: Acquire several sets of preferred adjustment data, wherein the preferred adjustment data include mold size, tilt angle, adjustment cycle, and defoaming rate.

[0100] In this embodiment, the mold dimensions include: length, width, height and cross-sectional shape of the mold.

[0101] Step S404: Iteratively train a machine learning regression model using the mold size and the defoaming rate as input until the difference between the output tilt angle and adjustment period and the actual tilt angle and adjustment period is less than an error threshold to obtain a target adjustment model.

[0102] Step S406: Input the mold size corresponding to the mutual inductor to be injected and the expected defoaming rate into the target adjustment model to obtain the tilt angle and adjustment cycle used for actual adjustment.

[0103] The target adjustment model can then quickly and accurately determine the desired tilt angle and adjustment period. Furthermore, since the defoaming rate is used as an input, it is also convenient to tailor the tilt angle and adjustment period for the casting of the same transformer model to specific process specifications, thereby improving process efficiency.

[0104] As a specific implementation, when the model of the transformer to be cast is LZZBJ9-10, the tilt angle is 15 degrees, and the adjustment cycle is 5 seconds / time, for a total of 6 times; at this time, a transformer with uniform and stable quality can be obtained.

[0105] While the present invention has been disclosed above with reference to preferred embodiments, this is not intended to limit the present invention. Persons skilled in the art will readily appreciate that various modifications and variations can be made without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the claims.

Claims

1. A casting method for a mutual inductor, characterized in that: The invention adopts a casting device for mutual inductors, which includes a casting tank and a mold that cooperate with each other; the casting tank includes a tank body, a casting platform, a conveying mechanism, a positioning mechanism and a feeding arm arranged in the tank body; the mold includes a lower mold and an upper mold that cooperate with each other; The tank body is a vacuum chamber with a vacuum degree range of 300Pa to 300000Pa. During the feeding process of the transformer to be cast and sealed, the tank body is subjected to multi-level vacuum degree control; The pouring platform includes a carrier, a plurality of pillars and a first magnetic disk; the first magnetic disk is embedded in the carrier; one end of each pillar supports the carrier and the other end is fixed to the bottom of the tank, and each pillar has the freedom to independently adjust its height in a direction perpendicular to the bottom of the tank; The transmission mechanism includes a first slide rail and a multi-axis clamp; the first slide rail is laid on the inner wall of the tank body, and the base of the multi-axis clamp is movably installed in the first slide rail; A second magnetic disk is provided at the bottom of the lower mold, and the magnetic properties of the second magnetic disk are opposite to those of the first magnetic disk; a plurality of first alignment marks are etched on the top of the lower mold; The upper mold includes a main body, a main pouring pipe, an auxiliary pouring pipe, a liquid level sensor, and a hanging piece; a plurality of second alignment marks are opened through the main body, and the shape and position of the second alignment marks correspond one-to-one with the first alignment marks; the main pouring pipe and the auxiliary pouring pipe are passed through the main body, and the liquid level sensor is installed inside the auxiliary pouring pipe; the hanging piece is arranged at intervals along the outer circumference of the main body and is movably clamped by the multi-axis clamping jaws; The alignment mechanism includes a second slide rail, a camera, and a mounting member; the second slide rail is laid on the inner top wall of the tank body, one end of the mounting member is fixed to the camera, and the other end is movably mounted in the second slide rail; The feed arm includes a feeding pipe, which is a stretchable structure with freedom along its axial direction; the feeding pipe is movably clamped by the multi-axis clamping jaws and movably plugged into the main pouring pipe; The corresponding pouring method includes the following steps: When it is determined that the lower mold is located in a preset area of ​​the carrier in the casting platform, the first magnetic disk and the second magnetic disk are controlled to start magnetic attraction; Obtain the model of the lower mold, use the multi-axis clamp based on the conveying mechanism to clamp the upper mold of the corresponding model, and superimpose it on the lower mold; at the same time, vacuum the tank body to 300~500Pa; The alignment camera is called to take pictures of each alignment mark, and the upper and lower molds are judged to be complete when the overlap between the first alignment mark on the lower mold and the second alignment mark on the upper mold at the corresponding position is greater than a preset value; When it is determined that the multi-axis gripper and the alignment camera are both placed in the initial positions, the multi-axis gripper is called again to grip the injection tube to insert it into the main pouring tube of the upper mold, and injection is started; The injection is stopped when the injection height in the lower mold reaches a preset height, as determined by a liquid level sensor in the auxiliary pouring pipe of the upper mold.

2. The casting method for a mutual inductor according to claim 1, characterized in that: The method comprises: determining, based on a liquid level sensor in an auxiliary pouring pipe of the upper mold, that the injection height in the lower mold reaches a preset height before stopping the injection; During the injection process, the pillars of the pouring platform are cyclically adjusted at a preset height and a preset frequency to periodically adjust the inclination angle of the mold according to a preset rule.

3. The casting method for a mutual inductor according to claim 2, characterized in that: After the liquid level sensor in the auxiliary pouring pipe of the upper mold determines that the injection height in the lower mold reaches a preset height, the injection is stopped; comprising: After a preset period of rest, the injection pipe is opened to carry out the first feeding until the liquid level reaches a preset height after the first feeding, and then the feeding is stopped; After the vacuum degree in the tank body is increased to 30000~50000Pa, the injection pipe is opened to carry out the second feeding until the liquid level reaches the preset height after the second feeding, and then the feeding is stopped; After the vacuum degree in the tank body is increased to 100000~300000Pa, the injection pipe is opened to carry out the third feeding until the liquid level reaches the preset height after the third feeding, and the feeding is stopped; During the first feeding, the second feeding and the third feeding processes, the pillars of the pouring platform are cyclically adjusted at a preset height and a preset frequency to periodically adjust the inclination angle of the mold according to a preset rule.

4. The casting method for a mutual inductor according to claim 2 or 3, characterized in that: The method includes obtaining the tilt angle and adjustment cycle of the mold; including: Acquire several sets of preferred adjustment data, wherein the preferred adjustment data include mold size, tilt angle, adjustment cycle and defoaming rate; Iteratively training a machine learning regression model using the mold size and the defoaming rate as input until the difference between the output tilt angle and adjustment period and the actual tilt angle and adjustment period is less than an error threshold to obtain a target adjustment model; The mold size corresponding to the mutual inductor to be injected and the expected defoaming rate are input into the target adjustment model to obtain the tilt angle and adjustment cycle used for actual adjustment.

5. The casting method for a mutual inductor according to claim 4, characterized in that: include: When the model of the transformer to be cast is LZZBJ9-10, the tilt angle is 15 degrees, and the adjustment cycle is 5 seconds per time, for a total of 6 times.

6. The casting method for a mutual inductor according to claim 1, characterized in that: It includes a plurality of pressure sensors; the pressure sensors are all installed on the carrier, and the pressure sensors correspond to the pre-placement areas of the lower mold one by one.

7. The casting method for a mutual inductor according to claim 1, characterized in that: include: The injection pipe includes a first magnetic ring, and the main pouring pipe includes a second magnetic ring; the first magnetic ring is sleeved on the remaining end of the injection pipe, and the second magnetic ring is sleeved on the remaining end of the main pouring pipe.

8. The casting method for a mutual inductor according to claim 1, characterized in that: include: There are four pillars in total, which are arranged at the four corners of the carrier; the pillars include a linear cylinder, a first fixing member and a second fixing member; the first fixing member is fixed to the base of the linear cylinder, and the second fixing member is fixed to the movable axis of the linear cylinder.

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