Transformer iron core rapid assembly system and assembly method thereof

Abstract

The invention discloses a transformer iron core rapid assembling system and an assembling method thereof, and belongs to the field of transformer iron core machining. The transformer iron core rapid assembling system comprises a conveying belt assembly, a jig structure, an assembling assembly, a first workbench and a second workbench; the conveying belt assembly is arranged in the X-axis direction, and the jig structure is arranged on the conveying belt assembly and used for bearing a lower iron yoke to be assembled. The first assembling assembly is arranged on the conveying belt assembly in a crossing mode in the Y-axis direction. The first workbench and the second workbench are arranged on the two sides, in the Y-axis direction, of the first assembling assembly correspondingly. According to the transformer iron core rapid assembly system and the assembly method thereof, through cooperative cooperation of the conveyor belt assembly and the X / Y / Z axis moving unit, automatic rapid clamping and sleeving of insulation paper and a winding are achieved, the problem that traditional manual assembly is low in efficiency is solved, high-precision assembly work is achieved, and full automation of the assembly process is achieved.

Description

Technical Field

[0001] The invention belongs to the field of transformer core processing, and in particular relates to a transformer core rapid assembly system and an assembly method thereof. Background Art

[0002] With the rapid development of new energy and high-end equipment manufacturing, the transformer market is placing higher demands on the production capacity and performance of iron cores. However, the error range of traditional assembly processes can no longer meet these standards, and the production capacity bottleneck of manual assembly is becoming increasingly prominent.

[0003] In the field of transformer core manufacturing, existing systems often suffer from single functions and insufficient coordination. For example, traditional conveying devices can only transport workpieces in a linear manner, unable to precisely align with assembly mechanisms and adapt to spatial posture adjustments during insulation paper sleeve insertion. While some equipment is equipped with visual inspection modules, these can only identify the presence of workpieces and are unable to collect real-time position coordinates and feed them back to the control system, resulting in cumulative assembly errors.

[0004] Therefore, we introduce a transformer core rapid assembly system and an assembly method thereof to solve the above problems. Summary of the Invention

[0005] In response to one or more of the above-mentioned defects or improvement needs in the prior art, the present invention provides a transformer core rapid assembly system and assembly method thereof, which realizes the automated rapid clamping and splicing of insulating paper and windings through the coordinated cooperation of a conveyor belt assembly and an X / Y / Z-axis moving unit, thereby solving the problem of low efficiency of traditional manual assembly; at the same time, with the help of a first detection camera and a data processing module, it accurately collects workpiece position information and controls the movement of the clamping claw, thereby achieving high-precision assembly operations, reducing manual intervention, and realizing full automation of the assembly process.

[0006] To achieve the above object, the present invention provides a transformer core rapid assembly system, which includes a conveyor belt assembly, a fixture structure and an assembly assembly, as well as a first workbench and a second workbench; The conveyor belt assembly is arranged along the X-axis direction, and the fixture structure is arranged on the conveyor belt assembly for carrying the lower iron yoke to be assembled; the first assembly assembly is arranged across the conveyor belt assembly along the Y-axis direction; The first assembly component includes two bracket structures, the two bracket structures are respectively arranged on both sides of the conveyor belt assembly in the Y-axis direction; an X-axis moving unit is provided on the bracket, and a Y-axis moving module is provided between the two X-axis moving units; two sliders are provided on the Y-axis moving module at intervals along the X-axis direction, each of the sliders is provided with a Z-axis moving unit, and a clamping claw is provided on the telescopic unit of the Z-axis moving module; and the movement directions of the two clamping claws are opposite; The first workbench and the second workbench are respectively arranged on both sides of the first assembly component in the Y-axis direction, and the first workbench and the second workbench are used to place the insulating paper and the winding structure to be assembled respectively; At the same time, a first detection camera is arranged under each slider to collect image data and position information of the lower iron yoke, and when the clamp moves to above the first workbench or the second workbench with the X-axis moving unit, the Y-axis moving unit and the Z-axis moving unit, the image data and position information of the workpiece to be assembled on the workbench are collected.

[0007] As a further improvement of the present invention, it further includes a second assembly component, which is arranged across the conveyor belt assembly along the Y-axis direction and is spaced apart from the first assembly group in the X-axis direction; It includes a frame body and two first telescopic units, a second telescopic unit and a third telescopic unit located on opposite sides of the frame body; The first telescopic unit is arranged along the Y-axis direction, the second telescopic unit is arranged on the telescopic end of the first telescopic unit along the X-axis direction, and the third telescopic unit is arranged on the movable end of the second telescopic unit.

[0008] As a further improvement of the present invention, a pressing block is further provided on the telescopic end of the third telescopic unit for pressing the upper iron yoke onto the lower iron yoke.

[0009] As a further improvement of the present invention, a second detection camera is further provided at the top of the inner cavity of the frame, for collecting image data of the lower iron yoke located at the bottom of the frame.

[0010] As a further improvement of the present invention, the fixture assembly includes a carrier plate and a clamping structure; the clamping mechanism is arranged on the linear module and is used to clamp and limit the lower iron yoke.

[0011] As a further improvement of the present invention, a linear module is provided on the carrier plate along the X-axis direction, and the clamping structure is provided on the linear module for driving the linear module to perform fine adjustment along the X-axis direction.

[0012] As a further improvement of the present invention, an infrared receiving sensor is further provided on the carrier board; Correspondingly, an infrared transmitter is provided on the frame, which is communicatively connected with the infrared receiver and is used to locate the position of the carrier board.

[0013] As a further improvement of the present invention, it also includes a data processing module, which is communicatively connected to the first detection camera and the second detection camera respectively, for receiving image data collected by the first detection camera and the second detection camera, and collecting position information according to the image data to control the first assembly component and the second assembly component, as well as the conveyor belt component to operate in coordination.

[0014] On this basis, the present invention also provides a method for rapid assembly of a transformer core, which is implemented using the above-mentioned rapid assembly system. The method comprises the following steps: Assembling the iron yoke on the iron core to the jig assembly, and assembling the jig assembly to the conveyor belt assembly; The conveyor belt transports the jig assembly loaded with the lower iron yoke to the position of the first assembly assembly; The first assembly component drives the clamping jaws to move through the X-axis moving unit, the Y-axis moving unit, and the Z-axis moving unit to first clamp the insulating paper, then clamp the corresponding amount of insulating paper according to the number of vertical cores of the lower iron yoke, and then sleeve the insulator onto the vertical core of the lower iron yoke; Then adjust the position of the lower iron yoke in the X-axis direction, use the clamping claws on the other side to clamp the corresponding number of coil windings, and assemble them on the vertical core of the lower iron yoke; Complete the assembly of the lower iron yoke.

[0015] The above-mentioned improved technical features can be combined with each other as long as they do not conflict with each other.

[0016] In general, the above technical solutions conceived by the present invention have the following beneficial effects compared with the prior art: The transformer core rapid assembly system and assembly method of the present invention realize the automated rapid clamping and socketing of insulating paper and windings through the coordinated cooperation of the conveyor belt assembly and the X / Y / Z axis moving unit, thereby solving the problem of low efficiency of traditional manual assembly. At the same time, with the help of the first detection camera and the data processing module, the workpiece position information is accurately collected and the movement of the clamping claw is controlled to achieve high-precision assembly operations, reduce manual intervention, and realize full automation of the assembly process. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 2 is a schematic diagram of the overall three-dimensional structure of the transformer core rapid assembly system according to an embodiment of the present invention; Figure 2 yes Figure 1 A schematic diagram of the overall three-dimensional structure from another perspective; Figure 3 2 is a schematic diagram of the overall structure of the first assembly component in the transformer core rapid assembly system according to an embodiment of the present invention; Figure 4 yes Figure 3 Schematic diagram of the overall structure from another perspective; Figure 5 2 is a schematic diagram of the overall structure of the second assembly component in the transformer core rapid assembly system according to an embodiment of the present invention; Figure 6 2 is a schematic diagram of the overall structure of the jig assembly in the transformer core rapid assembly system according to an embodiment of the present invention; In all the drawings, the same reference numerals represent the same technical features, specifically: 100. Conveyor belt assembly 200, fixture assembly; 201, carrier plate; 202, linear module; 203, clamping structure; 300, lower iron yoke; 400, first assembly component; 401, bracket; 402, X-axis moving unit; 403, Y-axis moving unit; 404, Z-axis moving unit; 405, gripper; 406, first detection camera; 500, second assembly component; 501, frame; 502, first telescopic unit; 503, second telescopic unit; 504, third telescopic unit; 505, second detection camera; 600, first workbench; 601, insulating paper; 700. Second workbench; 602. Winding structure. DETAILED DESCRIPTION

[0018] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments.

[0019] 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. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0020] See also Figures 1 to 6The transformer core rapid assembly system in the preferred embodiment of the present invention is specifically, the rapid assembly system in the preferred embodiment of the present invention includes a conveyor belt assembly 100, a fixture structure and an assembly assembly, as well as a first workbench 600 and a second workbench 700; the conveyor belt assembly 100 is arranged along the X-axis direction, and the fixture structure is arranged on the conveyor belt assembly 100, for carrying the lower iron yoke 300 to be assembled; the first assembly assembly 400 is arranged across the conveyor belt assembly 100 along the Y-axis direction; wherein the first assembly assembly 400 includes two brackets 401 structures, and the two brackets 401 structures are respectively arranged on both sides of the conveyor belt assembly 100 in the Y-axis direction; and an X-axis moving unit 402 is provided on the bracket 401, and a Y-axis moving module is provided between the two X-axis moving units 402; and on the Y-axis moving module, a Y-axis moving module is provided between the two X-axis moving units 402; Two sliders are arranged at intervals, each slider is provided with a Z-axis moving unit 404, and a clamp 405 is provided on the telescopic unit of the Z-axis moving module; and the movement directions of the two clamps 405 are opposite; the first workbench 600 and the second workbench 700 are respectively arranged on both sides of the first assembly component 400 in the Y-axis direction, and the first workbench 600 and the second workbench 700 are respectively used to place the insulating paper 601 and the winding structure 602 to be assembled; at the same time, a first detection camera 406 is provided under each slider for collecting image data and position information of the lower iron yoke 300, and when the clamp 405 moves to above the first workbench 600 or the second workbench 700 with the X-axis moving unit 402, the Y-axis moving unit 403 and the Z-axis moving unit 404, the image data and position information of the workpiece to be assembled on the workbench are collected.

[0021] More specifically, the rapid assembly system in the preferred embodiment of the present invention also includes a second assembly component 500, which is arranged across the conveyor belt component 100 along the Y-axis direction and is spaced apart from the first assembly group in the X-axis direction; it includes a frame 501 and two first telescopic units 502, a second telescopic unit 503 and a third telescopic unit 504 located on opposite sides of the frame 501; wherein the first telescopic unit 502 is arranged along the Y-axis direction, and the second telescopic unit 503 is arranged along the X-axis direction on the telescopic end of the first telescopic unit 502, and the third telescopic unit 504 is arranged on the movable end of the second telescopic unit 503.

[0022] Furthermore, a pressing block is provided at the telescopic end of the third telescopic unit 504 for pressing the upper iron yoke onto the lower iron yoke 300. At the same time, a second detection camera 505 is provided at the top of the inner cavity of the frame 501 for collecting image data of the lower iron yoke 300 at the bottom of the frame 501.

[0023] During actual use, the second assembly component 500 is spaced apart from the first assembly component 400. The first telescopic unit 502 of the Y axis, the second telescopic unit 503 of the X axis, and the third telescopic unit 504 of the Z axis in the frame 501 work together to drive the pressing block. The second detection camera 505 on the top monitors the position of the lower iron yoke 300 in real time. Through multi-axis linkage, the upper iron yoke is accurately pressed to the lower iron yoke 300 to form a closed magnetic circuit, replacing the traditional manual pressing operation, ensuring that the air gap in the magnetic circuit is evenly distributed, and improving the electromagnetic performance of the iron core.

[0024] In more detail, the jig assembly 200 includes a carrier plate 201 and a clamping structure 203. The clamping mechanism is mounted on the linear module 202 and is used to clamp and limit the position of the lower iron yoke 300. Furthermore, preferably, the linear module 202 is mounted on the carrier plate 201 along the X-axis, and the clamping structure 203 is mounted on the linear module 202 to drive the linear module 202 for fine adjustment along the X-axis.

[0025] Furthermore, an infrared receiving sensor is installed on carrier plate 201; correspondingly, an infrared transmitter is installed on frame 501, which is in communication with the infrared receiver and is used to locate the position of carrier plate 201. The jig assembly 200, through the cooperation of the linear module 202 and the clamping structure 203 on carrier plate 201, can adjust the clamping position according to the core specifications. Combined with the positioning and calibration of the infrared receiving sensor and the transmitter on frame 501, it achieves adaptive clamping and precise positioning for cores with different numbers of cores, solving the time-consuming problem of traditional fixed jig changeovers and enhancing the production line's flexible production capabilities.

[0026] In addition, the preferred embodiment of the present invention also includes a data processing module, which is respectively connected to the first detection camera 406 and the second detection camera 505 for receiving image data collected by the first detection camera 406 and the second detection camera 505, and collecting position information according to the image data to control the first assembly component 400 and the second assembly component 500, as well as the conveyor belt component 100 to operate in coordination.

[0027] In actual use, the conveyor assembly 100 is positioned along the X-axis, with the jig structure mounted on the conveyor. Its carrier plate 201, driven by a linear module 202, drives the clamping structure 203 for fine-tuning along the X-axis. This, combined with communication and positioning between the infrared receiving sensor and the infrared emitter on the frame 501, ensures stable clamping and positional alignment of the lower yoke 300, eliminating the offset problem caused by traditional manual handling and providing a precise reference for subsequent assembly. The first assembly assembly 400, straddling the conveyor along the Y-axis, comprises a three-axis linkage structure composed of an X-axis moving unit, a Y-axis moving module on the frame 401, and a Z-axis moving unit on the slider. The gripper 405, driven by the slider, moves in opposite directions to synchronously grasp the workpiece. A first inspection camera 406 below the slider captures real-time image data of the lower yoke 300 and the workpiece on the workbench. This data is then processed by a data processing module to control the three-axis linkage, achieving precise connection of the insulating paper 601 to the number of cores and automated winding assembly. This replaces manual labor with a robotic arm, significantly improving assembly efficiency and consistency.

[0028] The data processing module and the first and second detection cameras 505 form a closed-loop control system, which receives image data in real time and calculates the workpiece position information, and synchronously controls the coordinated actions of the conveyor belt component 100, the first assembly component 400 and the second assembly component 500, forming an automatic control of the entire process from the sleeve connection of the insulating paper 601, the winding assembly to the pressing of the upper iron yoke, avoiding the accumulation of manual operation errors and improving the assembly accuracy and system stability.

[0029] On this basis, the present invention also provides a rapid assembly method for a transformer core, which is implemented using the above-mentioned rapid assembly system. The method includes the following steps: assembling the upper yoke of the core to the jig assembly 200, and assembling the jig assembly 200 to the conveyor belt assembly 100; the conveyor belt transports the jig assembly 200 loaded with the lower yoke 300 to the position of the first assembly assembly 400; the first assembly assembly 400 drives the clamping jaw 405 to move through the X-axis moving unit 402, the Y-axis moving unit 403 and the Z-axis moving unit 404, first clamping the insulating paper 601, and then clamping the corresponding number of insulating papers 601 according to the number of vertical core columns of the lower yoke 300, and sleeve the insulator onto the vertical core column of the lower yoke 300; then adjust the position of the lower yoke 300 in the X-axis direction, use the clamping jaw 405 on the other side to clamp the corresponding number of coil windings, and assemble them to the vertical core column of the lower yoke 300; complete the assembly operation of the lower yoke 300.

[0030] The assembly method relies on the above-mentioned system. The lower iron yoke 300 is first fixed to the jig and transported to the assembly station by the conveyor belt. The first assembly component 400 completes the insulation paper 601 sleeve and winding assembly through the three-axis linkage clamp 405. Subsequently, the second assembly component 500 automatically presses the upper iron yoke. Each process is precisely coordinated through visual inspection and data processing, which simplifies the complex process of traditional manual assembly, reduces labor intensity, and significantly improves the efficiency and reliability of iron core assembly.

[0031] It will be easily understood by those skilled in the art that the above description is merely 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 scope of protection of the present invention.

Claims

1. A transformer core rapid assembly system, characterized in that: It includes a conveyor belt assembly, a fixture structure and an assembly assembly, as well as a first workbench and a second workbench; The conveyor belt assembly is arranged along the X-axis direction, and the fixture structure is arranged on the conveyor belt assembly for carrying the lower iron yoke to be assembled; the first assembly assembly is arranged across the conveyor belt assembly along the Y-axis direction; The first assembly component includes two bracket structures, the two bracket structures are respectively arranged on both sides of the conveyor belt assembly in the Y-axis direction; an X-axis moving unit is provided on the bracket, and a Y-axis moving module is provided between the two X-axis moving units; two sliders are provided on the Y-axis moving module at intervals along the X-axis direction, each of the sliders is provided with a Z-axis moving unit, and a clamp is provided on the telescopic unit of the Z-axis moving module; and the movement directions of the two clamps are opposite; The first workbench and the second workbench are respectively arranged on both sides of the first assembly component in the Y-axis direction, and the first workbench and the second workbench are used to place the insulating paper and the winding structure to be assembled respectively; At the same time, a first detection camera is arranged under each slider to collect image data and position information of the lower iron yoke, and when the clamp moves to above the first workbench or the second workbench with the X-axis moving unit, the Y-axis moving unit and the Z-axis moving unit, the image data and position information of the workpiece to be assembled on the workbench are collected.

2. The transformer core rapid assembly system according to claim 1, characterized in that: Also included is a second assembly component, which is arranged across the conveyor belt assembly along the Y-axis direction and is spaced apart from the first assembly group in the X-axis direction; It includes a frame body and two first telescopic units, a second telescopic unit and a third telescopic unit located on opposite sides of the frame body; The first telescopic unit is arranged along the Y-axis direction, the second telescopic unit is arranged on the telescopic end of the first telescopic unit along the X-axis direction, and the third telescopic unit is arranged on the movable end of the second telescopic unit.

3. The transformer core rapid assembly system according to claim 2, characterized in that: A pressing block is also provided on the telescopic end of the third telescopic unit for pressing the upper iron yoke onto the lower iron yoke.

4. The transformer core rapid assembly system according to claim 2, characterized in that: A second detection camera is also provided at the top of the inner cavity of the frame, for collecting image data of the lower iron yoke located at the bottom of the frame.

5. The transformer core rapid assembly system according to any one of claims 1 to 4, characterized in that: The fixture assembly includes a carrier plate and a clamping structure; the clamping mechanism is arranged on the linear module and is used to clamp and limit the lower iron yoke.

6. The transformer core rapid assembly system according to claim 5, characterized in that: A linear module is arranged on the carrier plate along the X-axis direction, and the clamping structure is arranged on the linear module to drive the linear module to perform fine adjustment along the X-axis direction.

7. The transformer core rapid assembly system according to claim 5, characterized in that: An infrared receiving sensor is also provided on the carrier board; Correspondingly, an infrared transmitter is provided on the frame, which is communicatively connected with the infrared receiver and is used to locate the position of the carrier board.

8. The transformer core rapid assembly system according to claim 5, characterized in that: It also includes a data processing module, which is respectively connected to the first detection camera and the second detection camera for receiving image data collected by the first detection camera and the second detection camera, and collecting position information according to the image data to control the first assembly component and the second assembly component, as well as the conveyor belt component to operate in coordination.

9. A method for quickly assembling a transformer core, characterized in that: The method is implemented using the rapid assembly system according to any one of claims 1 to 8, and comprises the following steps: Assembling the iron yoke on the iron core to the jig assembly, and assembling the jig assembly to the conveyor belt assembly; The conveyor belt transports the jig assembly loaded with the lower iron yoke to the position of the first assembly assembly; The first assembly component drives the clamping jaws to move through the X-axis moving unit, the Y-axis moving unit, and the Z-axis moving unit to first clamp the insulating paper, then clamp the corresponding amount of insulating paper according to the number of vertical cores of the lower iron yoke, and then sleeve the insulator onto the vertical core of the lower iron yoke; Then adjust the position of the lower iron yoke in the X-axis direction, use the clamping claws on the other side to clamp the corresponding number of coil windings, and assemble them on the vertical core of the lower iron yoke; Complete the assembly of the lower iron yoke.

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