High-frequency transformer ferrite core continuous assembly device and method

Abstract

The invention discloses a high-frequency transformer ferrite core continuous assembly device and method, and relates to the technical field of transformer production. A plurality of groups of electromagnet square columns are fixedly arranged on the inner periphery of a magnetic core lamination stacking area. Smooth guide assemblies are installed between the partition supporting frame and the transmission supporting box and comprise slope guide rollers inclining and lowering towards the magnetic core lamination stacking area, two stepping motors are fixedly installed on the supporting frame, one stepping motor is in driving connection with the slope guide roller of one smooth guide assembly, and the other stepping motor is in driving connection with the slope guide roller of the other smooth guide assembly. And the other stepping motor is in driving connection with the slope guide roller of the other smooth guide assembly. The side position frame is provided with a plurality of side position guide rollers used for guiding the magnetic core laminations to slide down along the slope guide rollers, and the side position frame is further provided with a photoelectric detection mechanism used for detecting the side end positions of the magnetic core laminations. A lifting mechanism used for driving the supporting frame to vertically ascend and descend is arranged under the supporting frame. According to the magnetic core lamination stacking device, excessive manual intervention is not needed, and rapid and continuous stacking operation of magnetic core laminations is achieved.

Description

Technical Field

[0001] The invention relates to the technical field of transformer production, and in particular to a device and method for continuously assembling ferrite cores of high-frequency transformers. Background Art

[0002] The assembly of ferrite cores is a crucial step in the manufacturing process of high-frequency transformers. The traditional method of transformer core lamination mainly relies on manual assembly, which has many disadvantages. First of all, the efficiency of manual assembly is extremely low. During manual operation, workers need to place and stack the core laminations one by one. Each operation takes a certain amount of time, and as the working time increases, workers are prone to fatigue, which further reduces work efficiency.

[0003] Secondly, manual assembly has large errors. Since it is difficult to ensure that the position and angle of each lamination are completely consistent, the assembled ferrite core has problems in dimensional accuracy and structural stability. Deviations in dimensional accuracy may affect the matching accuracy between the core and other components, and thus affect the overall performance of the high-frequency transformer; and insufficient structural stability may cause the core to loosen or shift during use, reducing the reliability and service life of the high-frequency transformer.

[0004] In summary, developing an efficient and precise continuous assembly equipment for high-frequency transformer ferrite cores to improve the production efficiency of high-frequency transformers, reduce production costs and improve product quality has become a problem that needs to be solved. Summary of the invention

[0005] In order to solve the above technical problems, the present invention is achieved through the following technical solutions:

[0006] The present invention provides a high-frequency transformer ferrite core continuous assembly device, the structure of which is as follows:

[0007] A plurality of sets of electromagnet square columns are fixedly arranged around the magnetic core stacking area, and a positioner is arranged on the upper side of the conjugate sheet pre-arranged in the magnetic core stacking. A support frame is arranged at all four directions of the magnetic core stacking area, and the support frame includes a partition support frame and a transmission support box located on both sides of the partition support frame. A smooth guide assembly is installed between the partition support frame and the transmission support box. The smooth guide assembly includes a slope guide roller that is inclined and lowered toward the magnetic core stacking area. Two stepper motors are fixedly installed on the support frame, one of which is connected to the slope guide roller of one of the smooth guide assemblies, and the other stepper motor is connected to the slope guide roller of the other smooth guide assembly. Side frames are fixedly installed on both sides of the support frame, and the side frames are equipped with a plurality of side guide rollers for guiding the magnetic core stacking to slide down along the slope guide rollers. The side frames are also equipped with a photoelectric detection mechanism for detecting the side end position of the magnetic core stacking. A lifting mechanism for driving the support frame to lift vertically is arranged directly below the support frame.

[0008] As a preferred technical solution of the device of the present invention: the magnetic core laminations include a first azimuth lamination directly clamped with the conjugate lamination, a second azimuth lamination adjacent to the first azimuth lamination, an electromagnet square column is arranged on the inner side of the overlapping position of the first azimuth lamination and the conjugate lamination, and an electromagnet square column is arranged on the inner side of the overlapping position of the first azimuth lamination and the second azimuth lamination.

[0009] As a preferred technical solution of the device of the present invention: a driving device for adjusting the height position and the pressure of the positioner is arranged above the positioner.

[0010] As a preferred technical solution of the device of the present invention: the photoelectric detection mechanism is equipped with a plurality of photoelectric probes which are continuously distributed and whose detection direction is vertically downward.

[0011] As a preferred technical solution of the device of the present invention: the slope guide roller, the vertical pressure roller and the edge guide roller are all roller structures made of rubber material.

[0012] As a preferred technical solution of the device of the present invention: the smooth guide assembly includes a plurality of vertical pressure rollers located directly below the slope guide roller at the lowest point, and the vertical pressure rollers are in extrusion contact with the outer sides of the stacked magnetic core laminations.

[0013] The present invention provides a method for continuously assembling a ferrite core of a high-frequency transformer, comprising the following contents:

[0014] S1. The conjugate piece is placed between the two electromagnet square columns in the middle position, and the conjugate piece is directly pressed down by the positioner.

[0015] S2. The feeding mechanism smoothly transfers the corresponding magnetic core stack to the smooth guide assembly, and the magnetic core stack falls into the slope guide roller. The stepper motor drives the slope guide rollers in their respective positions to rotate, driving the magnetic core stack to tilt and slide down, and the rubber guide roller rolls in contact with the side ends of the magnetic core stack.

[0016] S3. The photoelectric detection mechanism detects the real-time moving position of the side end of the magnetic core lamination:

[0017] When the real-time moving positions of the two side ends of the magnetic core stack are the same, the output speeds of the two stepper motors are the same, driving the slope guide rollers at their respective positions to drive the side ends of the magnetic core stack to move at the same speed.

[0018] When the real-time moving positions of the two side ends of the magnetic core stack are different: the speed of the stepper motor on the side where the lower end of the magnetic core stack is located decreases, and the speed of the slope guide roller driven by it decreases; the speed of the stepper motor on the side where the lower end of the magnetic core stack is located higher increases, and the speed of the slope guide roller driven by it increases; until the real-time moving positions of the two side ends of the magnetic core stack are the same or the photoelectric detection mechanism detects that the magnetic core stack is completely moved out of the slope guide roller.

[0019] S4. When the magnetic core stack is completely moved out of the slope guide roller, the photoelectric detection mechanism detects that the shielding signal of the magnetic core stack disappears, and the electromagnet square column in the corresponding position is energized once, and the magnetic core stack that is about to be stacked is magnetically attracted to assist the magnetic core stack to be stacked in place. Among them, every time the number of stacking reaches the preset m times, the lifting mechanism drives the support frame to move up the height Δh = m*D0, where D0 is the thickness of a single magnetic core stack.

[0020] S5. The magnetic core stack at the current position completes one stacking operation, and the magnetic core stacking operation at the next position is performed according to the contents of S2 to S4, and the stacking operation of all magnetic core stacks is completed periodically over and over again.

[0021] In the above assembly method: when the photoelectric detection mechanism on either side detects the signal that the magnetic core stack enters from above the slope guide roller, the stepper motor on the opposite side is started.

[0022] When the photoelectric detection mechanisms detect the signal that the magnetic core stack leaves the bottom of the slope guide roller, the stepper motor in the corresponding position is turned off.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] 1. The present invention adopts a continuous assembly method, with the help of a feeding mechanism, a stepper motor driving the sloped guide roller and a periodic operation process, to achieve rapid and continuous stacking of magnetic core laminations. Compared with manually placing one piece at a time, the assembly time is greatly reduced. At the same time, during the stacking process, whenever the number of stacking reaches a preset value, the lifting mechanism automatically drives the support frame to move up, without the need for manual frequent position adjustment, further improving the overall assembly efficiency.

[0025] 2. The present invention monitors the moving position of the side ends of the magnetic core stack in real time by setting a photoelectric detection mechanism. When the moving positions of the two side ends are different, the stepper motor speed is automatically adjusted so that the magnetic core stack can slide down and stack accurately along the slope guide roller. The electromagnet square column performs magnetic suction assistance when the magnetic core stack is completely moved out of the slope guide roller to ensure that it is stacked in place, effectively avoiding the dimensional accuracy and structural stability problems caused by inconsistent stacking positions and angles during manual assembly, and improving the assembly accuracy of the ferrite core.

[0026] 3. In the present invention, during the upward movement of the support frame, the vertical pressure roller further presses the stacked magnetic core laminations inward, further enhancing the structural stability of the magnetic core laminations after stacking, reducing the risk of loosening and displacement of the magnetic core during use, and improving the reliability and service life of the high-frequency transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the use status of the magnetic core continuous assembly device in the present invention.

[0028] Figure 2 It is a schematic diagram of the matching structure of the electromagnet square column, the positioner and the magnetic core lamination in the present invention.

[0029] Figure 3 It is a schematic diagram of the main structure for supplying magnetic core laminations in the present invention.

[0030] Figure 4 This is a schematic diagram of the single-side component structure for supplying magnetic core laminations in the present invention.

[0031] Figure 5 It is a schematic structural diagram of the support frame and related components below the smooth guide assembly in the present invention.

[0032] Among them: 1-magnetic core lamination, 101-conjugate lamination, 102-first azimuth lamination, 103-second azimuth lamination; 2-electromagnet square column; 3-positioner; 4-support frame, 401-partition support frame, 402-transmission support box; 5-smooth guide assembly, 501-slope guide roller, 502-vertical pressure roller; 6-side frame, 601-edge guide roller; 7-lifting mechanism; 8-photoelectric detection mechanism; 9-stepping motor. DETAILED DESCRIPTION

[0033] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0034] Embodiment 1: The present invention designs a high-frequency transformer ferrite core continuous assembly device, please refer to Figure 1 , Figure 4 The device is mainly composed of components related to the magnetic core lamination stacking area, a support frame 4, a smooth guide component 5, a side frame 6, a lifting mechanism 7 and a photoelectric detection mechanism 8. The magnetic core lamination stacking area is the main area of ​​the magnetic core assembly, and other auxiliary components are distributed around it to coordinately complete the assembly of the magnetic core lamination 1. The specific structural configuration is as follows:

[0035] Electromagnet square column 2: please refer to Figure 1 , Figure 2 , multiple groups of electromagnet square columns 2 are fixedly arranged around the magnetic core lamination stacking area. The magnetic core lamination 1 includes a first orientation lamination 102 directly clamped with the conjugate sheet 101, a second orientation lamination 103 adjacent to the first orientation lamination 102, an electromagnet square column 2 is arranged on the inner side of the overlapped position of the first orientation lamination 102 and the conjugate sheet 101, and an electromagnet square column 2 is also arranged on the inner side of the overlapped position of the first orientation lamination 102 and the second orientation lamination 103. The electromagnet square column 2 is energized when the magnetic core lamination 1 is completely moved out of the ramp guide roller 501, and the magnetic core lamination 1 that is about to be stacked is magnetically attracted to assist it in stacking in place.

[0036] Locator 3: See Figure 1 , Figure 2 The locator 3 is arranged on the upper side of the conjugate sheet 101 pre-configured in the magnetic core lamination, and a driving device for adjusting the height position and the pressure of the locator 3 is arranged above the locator 3. The locator 3 is used to directly press down the conjugate sheet 101 to ensure the stable position of the conjugate sheet 101 during the assembly process.

[0037] Support frame 4 structure: please refer to Figure 1 , Figure 3 , Figure 5 A support frame 4 is disposed around the magnetic core lamination stacking area. The support frame 4 includes a partition support frame 401 and a transmission support box 402 located on both sides of the partition support frame 401.

[0038] Smooth Guide Assembly 5: See Figure 1 , Figure 2 , Figure 4 , Figure 5A smooth guide assembly 5 is installed between the partition support frame 401 and the transmission support box 402, and the smooth guide assembly 5 includes a slope guide roller 501 that is tilted and lowered toward the magnetic core lamination stacking area. Two stepper motors 9 are fixedly installed on the support frame 4, one of which is drivingly connected to the slope guide roller 501 of one of the smooth guide assemblies 5, and the other stepper motor 9 is drivingly connected to the slope guide roller 501 of the other smooth guide assembly 5. The stepper motor 9 drives the slope guide roller 501 to rotate, driving the magnetic core lamination 1 to tilt and slide down. In addition, the smooth guide assembly 5 also includes a plurality of vertical pressure rollers 502 located directly below the slope guide roller 501 at the lowest point. The vertical pressure rollers 502 are in compression contact with the outer sides of the already stacked magnetic core laminations 1. During the upward movement of the support frame 4, the magnetic core laminations 1 are further squeezed inward to make the stacking tighter.

[0039] Side frame 6 and related parts: please refer to Figure 1 , Figure 2 , Figure 4 , Figure 5 , the side frames 6 are fixedly installed on both sides of the support frame 4, and the side frames 6 are equipped with a plurality of side guide rollers 601 for guiding the magnetic core stack 1 to slide down along the slope guide rollers 501. The side guide rollers 601 play the role of guiding the magnetic core stack 1 to ensure that it slides down stably on the slope guide rollers 501. The side frames 6 are also equipped with a photoelectric detection mechanism 8 for detecting the side end position of the magnetic core stack 1. The photoelectric detection mechanism 8 is equipped with a plurality of continuously distributed photoelectric probes with the detection direction vertically downward, which are used to monitor the moving position of the side end of the magnetic core stack 1 in real time.

[0040] Lifting mechanism 7: Please refer to Figure 1 , Figure 3 , Figure 5 A lifting mechanism 7 for driving the support frame 4 to vertically lift is provided directly below the support frame 4. Whenever the number of stacking reaches a preset m times, the lifting mechanism 7 drives the support frame 4 to move up by a height Δh=m*D0 (D0 is the thickness of a single magnetic core lamination 1).

[0041] In the present invention, the slope guide roller 501, the vertical pressure roller 502, and the edge guide roller 601 are all roller structures made of rubber material. The rubber roller body rolls in contact with the side ends of the magnetic core laminations 1, which can not only play a good guiding role, but also reduce damage to the magnetic core laminations 1.

[0042] Embodiment 2: The present invention designs a method for continuously assembling a ferrite core of a high-frequency transformer, and the specific method is as follows:

[0043] Step 1: Preparation: Place the conjugate sheet 101 between the two electromagnet square columns 2 in the middle position, press down the conjugate sheet 101 directly through the positioner 3, and use the driving device above the positioner 3 to adjust the height and pressure of the positioner 3 to ensure that the conjugate sheet 101 is stably placed.

[0044] Link 2: Conveying and sliding down of magnetic core stacks: The feeding mechanism smoothly transfers the corresponding magnetic core stacks 1 to the smooth guide assembly 5, and the magnetic core stacks 1 fall into the slope guide rollers 501. The stepper motor 9 drives the slope guide rollers 501 in their respective directions to rotate, driving the magnetic core stacks 1 to tilt and slide down. During this process, the rubber side guide rollers 601 and the slope guide rollers 501 roll in contact with the side ends of the magnetic core stacks 1, playing a guiding role.

[0045] Link 3, adjustment of the position of the magnetic core lamination: the photoelectric detection mechanism 8 detects the real-time moving position of the side ends of the magnetic core lamination 1. When the real-time moving positions of the two side ends of the magnetic core lamination 1 are the same, the two stepper motors 9 have the same output speed, driving the slope guide rollers 501 at their respective positions to drive the side ends of the magnetic core lamination 1 to move at the same speed; when the real-time moving positions of the two side ends of the magnetic core lamination 1 are different, the speed of the stepper motor 9 on the side where the lower position of the side end of the magnetic core lamination 1 is lowered decreases, and the speed of the slope guide roller 501 driven by it decreases; the speed of the stepper motor 9 on the side where the lower position of the side end of the magnetic core lamination 1 is higher increases, and the speed of the slope guide roller 501 driven by it increases, until the real-time moving positions of the two side ends of the magnetic core lamination 1 are the same or the photoelectric detection mechanism 8 detects that the magnetic core lamination 1 is completely moved out of the slope guide roller 501.

[0046] Link 4, magnetic suction assistance and support frame lifting: When the magnetic core stack 1 is completely moved out of the slope guide roller 501, the photoelectric detection mechanism 8 detects that the blocking signal of the magnetic core stack 1 disappears, and the electromagnet square column 2 in the corresponding position is energized once (for example, energized for 2 to 3 seconds), and the magnetic core stack 1 that is about to be stacked is magnetically attracted to assist the magnetic core stack 1 to be stacked in place. Whenever the number of stacking reaches the preset m times, the lifting mechanism 7 drives the support frame 4 to move up the height Δh=m*D0. During the upward movement of the support frame 4, the vertical pressure roller 502 further squeezes the already stacked magnetic core stack 1 inward, so that the magnetic core stack 1 is stacked more tightly.

[0047] Step 5, cyclic operation: the magnetic core stack 1 at the current position completes one stacking action, and the magnetic core stack 1 at the next position is operated according to the contents of steps 2 to 4, and the cycle is repeated to periodically complete the stacking operation of all the magnetic core stacks 1.

[0048] Stepper motor start and stop control: When the photoelectric detection mechanism 8 on either side detects the signal that the core stack 1 enters from above the slope guide roller 501, the stepper motor 9 on the opposite side is started, and the reverse adjustment is made so that the two side ends of the core stack 1 move forward in parallel; when the photoelectric detection mechanism 8 detects the signal that the core stack 1 leaves the bottom of the slope guide roller 501 (that is, the photoelectric detection mechanism cannot detect the core stack 1), the stepper motor 9 in the corresponding position is turned off.

[0049] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A high-frequency transformer ferrite core continuous assembly device, characterized in that: A plurality of groups of electromagnet square columns (2) are fixedly arranged around the stacking area of ​​the magnetic core stack (1), and a positioner (3) is arranged on the upper side of the conjugate sheet (101) pre-arranged on the magnetic core stack (1); A support frame (4) is arranged at all four sides of the stacking area of ​​the magnetic core laminations (1), the support frame (4) comprising a partition support frame (401) and a transmission support box (402) located on both sides of the partition support frame (401), a smooth guide assembly (5) is installed between the partition support frame (401) and the transmission support box (402), the smooth guide assembly (5) comprising a slope guide roller (501) inclined downward toward the stacking area of ​​the magnetic core laminations (1), and two stepper motors (9) are fixedly installed on the support frame (4), one of the stepper motors (9) is drivingly connected to the slope guide roller (501) of one of the smooth guide assemblies (5), and the other stepper motor (9) is drivingly connected to the slope guide roller (501) of the other smooth guide assembly (5); Side frames (6) are fixedly mounted on both sides of the support frame (4); the side frames (6) are provided with a plurality of edge guide rollers (601) for guiding the magnetic core stack (1) to slide down along the slope guide rollers (501); the side frames (6) are also provided with a photoelectric detection mechanism (8) for detecting the side end position of the magnetic core stack (1); A lifting mechanism (7) for driving the support frame (4) to vertically lift is provided directly below the support frame (4).

2. The device for continuously assembling ferrite cores of high-frequency transformers according to claim 1, characterized in that: The magnetic core lamination (1) comprises a first orientation lamination (102) directly clamped with a conjugate lamination (101), and a second orientation lamination (103) adjacent to the first orientation lamination (102); an electromagnet square column (2) is arranged on the inner side of the overlapped position between the first orientation lamination (102) and the conjugate lamination (101); and an electromagnet square column (2) is arranged on the inner side of the overlapped position between the first orientation lamination (102) and the second orientation lamination (103).

3. The device for continuously assembling ferrite cores of high-frequency transformers according to claim 1, characterized in that: A driving device for adjusting the height position and the pressure of the positioner (3) is arranged above the positioner (3).

4. The device for continuously assembling ferrite cores of high-frequency transformers according to claim 1, characterized in that: The photoelectric detection mechanism (8) is equipped with a plurality of photoelectric probes which are continuously distributed and whose detection direction is vertically downward.

5. The device for continuously assembling ferrite cores of high-frequency transformers according to claim 1, characterized in that: The slope guide roller (501), the vertical pressure roller (502), and the edge guide roller (601) are all roller structures made of rubber material.

6. The device for continuously assembling ferrite cores of high-frequency transformers according to claim 1, characterized in that: The smooth guide assembly (5) comprises a plurality of vertical pressure rollers (502) located directly below the slope guide roller (501) at the lowest point, and the vertical pressure rollers (502) are in compression contact with the outer sides of the stacked magnetic core laminations (1).

7. A method for continuously assembling ferrite cores of high-frequency transformers, characterized in that: S1. The conjugate sheet (101) is placed between the two electromagnet square columns (2) in the middle position, and the conjugate sheet (101) is directly pressed down by the positioner (3); S2. The feeding mechanism smoothly transfers the corresponding magnetic core stack (1) to the smooth guide assembly (5), and the magnetic core stack (1) falls into the slope guide roller (501). The stepper motor (9) drives the slope guide rollers (501) in their respective directions to rotate, driving the magnetic core stack (1) to tilt and slide down, and the rubber guide roller rolls in contact with the side ends of the magnetic core stack (1); S3. The photoelectric detection mechanism (8) detects the real-time moving position of the side end of the magnetic core lamination (1): When the real-time moving positions of the two side ends of the magnetic core stack (1) are the same, the two stepping motors (9) output the same rotation speed, driving the slope guide rollers (501) at their respective positions to drive the side ends of the magnetic core stack (1) to move at the same rotation speed; When the real-time moving positions of the two side ends of the magnetic core stack (1) are different: the speed of the stepper motor (9) on the side where the side end of the magnetic core stack (1) moves downwards to a lower position is reduced, and the speed of the slope guide roller (501) driven by it is reduced; the speed of the stepper motor (9) on the side where the side end of the magnetic core stack (1) moves downwards to a higher position is increased, and the speed of the slope guide roller (501) driven by it is increased; until the real-time moving positions of the two side ends of the magnetic core stack (1) are the same or the photoelectric detection mechanism (8) detects that the magnetic core stack (1) is completely moved out of the slope guide roller (501); S4. When the magnetic core stack (1) is completely moved out of the slope guide roller (501), the photoelectric detection mechanism (8) detects that the shielding signal of the magnetic core stack (1) disappears, and the electromagnet square column (2) in the corresponding position is energized once, and the magnetic core stack (1) that is about to be stacked is magnetically attracted once, thereby assisting the magnetic core stack (1) to be stacked in place; Wherein, whenever the number of stacking times reaches a preset m times, the lifting mechanism (7) drives the support frame (4) to move up by a height Δh=m*D0, where D0 is the thickness dimension of a single magnetic core laminate (1); S5. The magnetic core stack (1) at the current position completes one stacking operation, and the magnetic core stack (1) at the next position is operated according to the contents of steps S2 to S4, and the process is repeated to periodically complete the stacking operation of all the magnetic core stacks (1).

8. The method for continuously assembling ferrite cores of high-frequency transformers according to claim 7, characterized in that: When the photoelectric detection mechanism (8) on either side detects a signal that the magnetic core stack (1) enters from above the ramp guide roller (501), the stepping motor (9) on the opposite side is started; When the photoelectric detection mechanism (8) detects the signal that the magnetic core stack (1) leaves the bottom of the slope guide roller (501), the stepper motor in the corresponding position is turned off.

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