A continuous assembly device and method for ferrite cores of high-frequency transformers

Abstract

This invention discloses a continuous assembly device and method for ferrite cores of high-frequency transformers, relating to the field of transformer manufacturing technology. In this invention: multiple sets of electromagnetic square columns are fixedly arranged around the core lamination stacking area. A smooth guide assembly is installed between the partition support frame and the transmission support box. The smooth guide assembly includes inclined guide rollers that slope downwards towards the core lamination stacking area. Two stepper motors are fixedly mounted on the support frame; one stepper motor is driven and connected to the inclined guide roller of one smooth guide assembly, and the other stepper motor is driven and connected to the inclined guide roller of another smooth guide assembly. A side frame is configured with multiple edge guide rollers for guiding the core laminations down the inclined guide rollers. The side frame is also configured with a photoelectric detection mechanism for detecting the position of the side ends of the core laminations. A lifting mechanism for driving the support frame to move vertically is located directly below the support frame. This invention achieves rapid and continuous stacking of core laminations without requiring excessive manual intervention.

Description

Technical Field

[0001] This invention relates to the field of transformer manufacturing technology, and in particular to a continuous assembly device and method for ferrite cores of high-frequency transformers. Background Technology

[0002] In the manufacturing process of high-frequency transformers, the assembly of ferrite cores is a crucial step. Traditional transformer core lamination methods primarily rely on manual assembly, which has several drawbacks. First, manual assembly is extremely inefficient. During manual operation, workers need to place and stack the core laminations one by one, each operation consuming time. Furthermore, as working hours increase, workers are prone to fatigue, further reducing efficiency.

[0003] Secondly, manual assembly introduces significant errors. Because manual operation makes it difficult to ensure perfect consistency in the position and angle of each lamination, the assembled ferrite core suffers from issues in dimensional accuracy and structural stability. Deviations in dimensional accuracy can affect the fit between the core and other components, thus impacting the overall performance of the high-frequency transformer; while insufficient structural stability can lead to loosening or displacement of the core during use, reducing the reliability and lifespan of the high-frequency transformer.

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

[0005] To solve the above-mentioned technical problems, the present invention is achieved through the following technical solution:

[0006] This invention provides a continuous assembly device for ferrite cores of high-frequency transformers, the structure of which is as follows:

[0007] Multiple sets of electromagnetic columns are fixedly arranged around the core stacking area, and positioners are arranged on the upper side of the pre-configured conjugate plates of the core stacks. A support frame is arranged around each of the core stacking areas. The support frame includes a partition support frame and transmission support boxes located on both sides of the partition support frame. A smooth guide assembly is installed between the partition support frame and the transmission support boxes. The smooth guide assembly includes inclined guide rollers that slope downwards towards the core stacking area. Two stepper motors are fixedly installed on the support frame. One stepper motor is driven and connected to the inclined guide roller of one smooth guide assembly, and the other stepper motor is driven and connected to the inclined guide roller of the other smooth guide assembly. Side frames are fixedly installed on both sides of the support frame. The side frames are equipped with multiple edge guide rollers for guiding the core stacks down along the inclined guide rollers. The side frames are also equipped with photoelectric detection mechanisms for detecting the position of the side ends of the core stacks. A lifting mechanism for driving the support frame to move vertically is located directly below the support frame.

[0008] As a preferred technical solution of the device of the present invention: the magnetic core lamination includes a first orientation lamination that is directly snapped into the conjugate lamination and a second orientation lamination that is adjacent to the first orientation lamination. An electromagnet square post is arranged on the inner side of the position where the first orientation lamination and the conjugate lamination are overlapped, and an electromagnet square post is arranged on the inner side of the position where the first orientation lamination and the second orientation lamination are overlapped.

[0009] As a preferred technical solution of the device of the present invention: a driving device for adjusting the height and position of the positioner and the pressure applied 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 multiple continuously distributed photoelectric probes with the detection direction vertically downward.

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

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

[0013] This invention provides a method for continuous assembly of ferrite cores for high-frequency transformers, comprising the following:

[0014] S1. The conjugate plate is placed between the two electromagnets in the middle position, and the conjugate plate is pressed down directly by the positioner.

[0015] S2. The feeding mechanism smoothly transmits the corresponding magnetic core stack to the smooth guide assembly. The magnetic core stack falls into the inclined guide roller. The stepper motor drives the inclined guide roller in its respective position to rotate, causing the magnetic core stack to tilt and slide down. The rubber guide roller makes rolling contact with the side end of the magnetic core stack.

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

[0017] When the two ends of the magnetic core stack move to the same position in real time, the two stepper motors output the same speed, driving the inclined guide rollers at their respective positions to move the ends of the magnetic core stack at the same speed.

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

[0019] S4. When the magnetic core stack is completely removed from the inclined guide roller, the photoelectric detection mechanism detects the disappearance of the obstruction signal of the magnetic core stack. The corresponding electromagnet column is energized once to magnetically attract the magnetic core stack that is about to be stacked, assisting the magnetic core stack to be stacked in place. Whenever the number of stacking operations reaches a preset m times, the lifting mechanism drives the support frame to move upwards by a height Δh = m * D0, where D0 is the thickness of a single magnetic core stack.

[0020] S5. Once the current magnetic core stack has completed one stacking operation, proceed with the next magnetic core stacking operation according to steps S2 to S4, repeating this process periodically to complete the stacking operation of all magnetic core stacks.

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

[0022] When the photoelectric detection mechanism detects the signal that the magnetic core stack has left the bottom of the inclined guide roller, the stepper motor in the corresponding position is turned off.

[0023] Compared with existing technologies, the beneficial effects of this invention are:

[0024] 1. This invention employs a continuous assembly method, utilizing a feeding mechanism, a stepper motor-driven inclined guide roller, and a periodic operation process to achieve rapid and continuous stacking of magnetic core laminations. Compared to manual placement of each lamination one by one, this significantly reduces assembly time. Furthermore, during the stacking process, whenever the preset number of stacking operations is reached, a lifting mechanism automatically drives the support frame upwards, eliminating the need for frequent manual adjustments and further improving overall assembly efficiency.

[0025] 2. This invention uses a photoelectric detection mechanism to monitor the movement position of the magnetic core stack in real time. When the two ends move at different positions, the stepper motor speed is automatically adjusted, allowing the magnetic core stack to slide precisely down the inclined guide roller and stack accurately. An electromagnet column provides magnetic assistance when the magnetic core stack is completely removed from the inclined guide roller, ensuring proper stacking. This effectively avoids dimensional accuracy and structural stability issues caused by inconsistent stack positions and angles during manual assembly, thus improving the assembly accuracy of the ferrite core.

[0026] 3. In this invention, during the upward movement of the support frame, the vertical pressure roller further presses the already stacked magnetic core laminations inward, which further enhances the structural stability of the stacked magnetic core laminations, reduces the risk of loosening or displacement of the magnetic cores during use, and improves the reliability and service life of the high-frequency transformer. Attached Figure Description

[0027] Figure 1 This is a schematic diagram showing the usage state of the continuous magnetic core assembly device in this invention.

[0028] Figure 2 This is a schematic diagram of the cooperative structure of the electromagnet square column, the positioner, and the magnetic core laminations in this invention.

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

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

[0031] Figure 5 This is a schematic diagram of the structure of the support frame and related components below the smooth guide assembly in this invention.

[0032] Wherein: 1-Magnetic core lamination, 101-Conjugate lamination, 102-First orientation lamination, 103-Second orientation lamination; 2-Electromagnetic column; 3-Positioner; 4-Support frame, 401-Partition support frame, 402-Transmission support box; 5-Smooth guide assembly, 501-Inclined guide roller, 502-Vertical pressure roller; 6-Side frame, 601-Side guide roller; 7-Lifting mechanism; 8-Photoelectric detection mechanism; 9-Stepper motor. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0034] Example 1: This invention designs a continuous assembly device for high-frequency transformer ferrite cores. Please refer to [link / reference]. Figure 1 , Figure 4 The device mainly consists of components related to the magnetic core stacking area, a support frame 4, a smooth guide assembly 5, a side frame 6, a lifting mechanism 7, and a photoelectric detection mechanism 8. The magnetic core stacking area is the main area for magnetic core assembly, surrounded by other auxiliary components that work together to complete the assembly of the magnetic core stack 1. The specific structural configuration is as follows:

[0035] Electromagnet square column 2: Please refer to Figure 1 , Figure 2 Multiple sets of electromagnetic columns 2 are fixedly arranged around the magnetic core stack area. The magnetic core stack 1 includes a first-position stack 102 directly engaged with the conjugate stack 101 and a second-position stack 103 adjacent to the first-position stack 102. Electromagnetic columns 2 are arranged on the inner side of the stacking position of the first-position stack 102 and the conjugate stack 101, and electromagnetic columns 2 are also arranged on the inner side of the stacking position of the first-position stack 102 and the second-position stack 103. The electromagnetic columns 2 are energized when the magnetic core stack 1 is completely removed from the inclined guide roller 501, and magnetically attract the magnetic core stack 1 that is about to be stacked, assisting it in being stacked in place.

[0036] Positioner 3: Please refer to Figure 1 , Figure 2 A positioner 3 is disposed on the upper side of the pre-configured conjugate sheet 101 of the magnetic core lamination. A drive device for adjusting the height and pressure of the positioner 3 is disposed above the positioner 3. The positioner 3 is used to directly press down on the conjugate sheet 101 to ensure the stability of the 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 provided around the magnetic core 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 Component 5: Please refer to 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. The smooth guide assembly 5 includes a ramp guide roller 501 that slopes downward toward the magnetic core stack area. Two stepper motors 9 are fixedly mounted on the support frame 4. One stepper motor 9 is driven by the ramp guide roller 501 of one of the smooth guide assemblies 5, and the other stepper motor 9 is driven by the ramp guide roller 501 of the other smooth guide assembly 5. The stepper motor 9 drives the ramp guide roller 501 to rotate, causing the magnetic core stack 1 to slope downward. In addition, the smooth guide assembly 5 also includes multiple vertical pressure rollers 502 located directly below the ramp guide roller 501 at the lowest point. The vertical pressure rollers 502 make pressing contact with the outer side of the already stacked magnetic core stack 1, further pressing the magnetic core stack 1 inward during the upward movement of the support frame 4, making the stacking more compact.

[0039] Side frame 6 and related components: Please refer to Figure 1 , Figure 2 , Figure 4 , Figure 5 Side frames 6 are fixedly installed on both sides of the support frame 4. The side frames 6 are equipped with multiple side guide rollers 601 for guiding the magnetic core stack 1 to slide down the inclined guide roller 501. The side guide rollers 601 guide the magnetic core stack 1 and ensure its stable sliding down the inclined guide roller 501. The side frames 6 are also equipped with a photoelectric detection mechanism 8 for detecting the position of the side end of the magnetic core stack 1. The photoelectric detection mechanism 8 is equipped with multiple continuously distributed photoelectric probes with the detection direction vertically downward, for real-time monitoring of the movement position of the side end of the magnetic core stack 1.

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

[0041] In this invention, the inclined guide roller 501, the vertical pressure roller 502, and the edge guide roller 601 are all roller structures made of rubber. The rubber rollers make rolling contact with the side ends of the magnetic core stack 1, which can not only provide good guidance but also reduce damage to the magnetic core stack 1.

[0042] Example 2: This invention designs a continuous assembly method for ferrite cores of high-frequency transformers, the specific method is as follows:

[0043] Step 1: Preparation: Place the conjugate plate 101 between the two electromagnet pillars 2 in the middle position, and press the conjugate plate 101 down directly through the positioner 3. Use the drive device above the positioner 3 to adjust the height of the positioner 3 and the pressure applied to ensure that the conjugate plate 101 is placed stably.

[0044] Step 2: Core Stack Transfer and Sliding: The feeding mechanism smoothly transfers the corresponding core stack 1 to the smooth guide assembly 5, and the core stack 1 falls into the inclined guide roller 501. The stepper motor 9 drives the inclined guide rollers 501 in their respective positions to rotate, causing the core stack 1 to slide down at an angle. During this process, the rubber side guide rollers 601 and the inclined guide rollers 501 roll in contact with the side ends of the core stack 1, playing a guiding role.

[0045] Step 3: Adjustment of the position of the magnetic core stack: The photoelectric detection mechanism 8 detects the real-time movement position of the side end of the magnetic core stack 1. When the real-time movement positions of both sides of the magnetic core stack 1 are the same, the two stepper motors 9 output the same speed, driving the inclined guide rollers 501 at their respective positions to move the side end of the magnetic core stack 1 at the same speed; when the real-time movement positions of the two sides of the magnetic core stack 1 are different, the speed of the stepper motor 9 on the side where the lower position of the magnetic core stack 1 is moved decreases, and the speed of the inclined guide roller 501 it drives decreases; the speed of the stepper motor 9 on the side where the lower position of the magnetic core stack 1 is moved increases, and the speed of the inclined guide roller 501 it drives increases, until the real-time movement positions of both sides of the magnetic core stack 1 are the same or the photoelectric detection mechanism 8 detects that the magnetic core stack 1 has completely moved out of the inclined guide roller 501.

[0046] Step 4: Magnetic Attraction Assistance and Support Frame Lifting: When the magnetic core stack 1 is completely removed from the inclined guide roller 501, the photoelectric detection mechanism 8 detects the disappearance of the blocking signal of the magnetic core stack 1. The corresponding electromagnet column 2 is energized once (e.g., energized for 2-3 seconds) to magnetically attract the magnetic core stack 1 that is about to be stacked, assisting 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 a 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, making the magnetic core stack 1 more tightly stacked.

[0047] Step 5, Cyclic Operation: After the current magnetic core stack 1 completes one stacking action, the operation of the next magnetic core stack 1 is carried out according to the content of Steps 2 to 4. This process is repeated until all magnetic core stacks 1 are stacked periodically.

[0048] Stepper motor start / stop control: When the photoelectric detection mechanism 8 on either side detects a signal that the magnetic core stack 1 has entered from above the inclined guide roller 501, the stepper motor 9 on the opposite side starts, and so on in reverse, so that the two ends of the magnetic core stack 1 move forward side by side; when the photoelectric detection mechanism 8 detects a signal that the magnetic core stack 1 has left from the bottom of the inclined guide roller 501 (that is, the photoelectric detection mechanism can no longer detect the magnetic core stack 1), the stepper motor 9 in the corresponding position turns 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 within the protection scope of the present invention.

Claims

1. A continuous assembly device for ferrite cores of high-frequency transformers, characterized in that: Multiple sets of electromagnet square columns (2) are fixedly arranged around the stacked area of ​​the magnetic core stack (1), and a positioner (3) is arranged on the upper side of the pre-configured conjugate plate (101) of the magnetic core stack (1). A support frame (4) is arranged around the stacking area of ​​the magnetic core stack (1). 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). A smooth guide assembly (5) is installed between the partition support frame (401) and the transmission support box (402). The smooth guide assembly (5) includes a ramp guide roller (501) that slopes downward toward the stacking area of ​​the magnetic core stack (1). Two stepper motors (9) are fixedly installed on the support frame (4). One stepper motor (9) is driven to the ramp guide roller (501) of one of the smooth guide assemblies (5), and the other stepper motor (9) is driven to the ramp guide roller (501) of the other smooth guide assembly (5). The support frame (4) is fixedly installed with side frames (6) on both sides. The side frames (6) are equipped with multiple side guide rollers (601) for guiding the magnetic core stack (1) to slide down the inclined guide roller (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 support frame (4) is provided with a lifting mechanism (7) for driving the support frame (4) to rise and fall vertically.

2. The continuous assembly device for high-frequency transformer ferrite cores according to claim 1, characterized in that: The magnetic core lamination (1) includes a first orientation lamination (102) directly snapped into the conjugate lamination (101) and a second orientation lamination (103) adjacent to the first orientation lamination (102). An electromagnetic column (2) is arranged inside the position where the first orientation lamination (102) and the conjugate lamination (101) are stacked. An electromagnetic column (2) is arranged inside the position where the first orientation lamination (102) and the second orientation lamination (103) are stacked.

3. The continuous assembly device for high-frequency transformer ferrite cores according to claim 1, characterized in that: The positioner (3) is equipped with a drive device for adjusting the height and pressure of the positioner (3).

4. The continuous assembly device for high-frequency transformer ferrite cores according to claim 1, characterized in that: The photoelectric detection mechanism (8) is equipped with multiple continuously distributed photoelectric probes with the detection direction vertically downward.

5. The continuous assembly device for high-frequency transformer ferrite cores according to claim 1, characterized in that: The smooth guide assembly (5) includes a plurality of vertical pressure rollers (502) located directly below the ramp guide roller (501) at the lowest point, the vertical pressure rollers (502) being pressed into contact with the outer side of the already stacked magnetic core laminations (1).

6. The continuous assembly device for high-frequency transformer ferrite cores according to claim 5, characterized in that: The inclined guide roller (501), vertical pressure roller (502), and edge guide roller (601) are all made of rubber.

7. A method for continuous assembly of ferrite cores for high-frequency transformers, characterized in that: S1. The conjugate plate (101) is placed between the two electromagnet square pillars (2) in the middle position, and the conjugate plate (101) is pressed down directly by the positioner (3). S2. The feeding mechanism smoothly transmits the corresponding magnetic core stack (1) to the smooth guide component (5). The magnetic core stack (1) falls into the inclined guide roller (501). The stepper motor (9) drives the inclined guide roller (501) in its respective position to rotate, causing the magnetic core stack (1) to tilt and slide down. The rubber guide roller rolls and the side end of the magnetic core stack (1) make rolling contact. S3. Photoelectric detection mechanism (8) detects the real-time movement position of the side end of the magnetic core stack (1): When the two ends of the magnetic core stack (1) move to the same position in real time, the two stepper motors (9) output the same speed, driving the inclined guide rollers (501) at their respective positions to drive the ends of the magnetic core stack (1) to move at the same speed. When the real-time moving positions of the two ends of the magnetic core stack (1) are different: the speed of the stepper motor (9) on the side where the lower position of the magnetic core stack (1) is lower, and the speed of the inclined guide roller (501) it drives is lower; the speed of the stepper motor (9) on the side where the lower position of the magnetic core stack (1) is higher, and the speed of the inclined guide roller (501) it drives is increased; until the real-time moving positions of the two ends of the magnetic core stack (1) are the same or the photoelectric detection mechanism (8) detects that the magnetic core stack (1) has completely moved out of the inclined guide roller (501). S4. When the magnetic core stack (1) is completely removed from the inclined guide roller (501), the photoelectric detection mechanism (8) detects that the blocking signal of the magnetic core stack (1) has disappeared, and the corresponding electromagnet column (2) is energized once to magnetically attract the magnetic core stack (1) that is about to be stacked, assisting the magnetic core stack (1) to be stacked in place. Wherein, 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, where D0 is the thickness of a single magnetic core stack (1); S5. The magnetic core stack (1) in the current position completes one stacking operation. Then, according to the content of steps S2 to S4, the magnetic core stack (1) in the next position is operated. This process is repeated until all magnetic core stacks (1) are stacked.

8. The continuous assembly method for a high-frequency transformer ferrite core 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) has entered from above the inclined guide roller (501), the stepper motor (9) on the opposite side is started. When the photoelectric detection mechanism (8) detects the signal that the magnetic core stack (1) has left the bottom of the inclined guide roller (501), the stepper motor in the corresponding position is turned off.

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