A transformer core rapid assembly system and an assembly method thereof

Abstract

The application discloses a transformer core rapid assembly system and an assembly method thereof, and belongs to the field of transformer core processing. The transformer core rapid assembly system comprises a conveying belt assembly, a jig assembly and an assembly assembly, and a first workbench and a second workbench. The conveying belt assembly is arranged along the X-axis direction, and the jig assembly is arranged on the conveying belt assembly and used for bearing a lower iron yoke to be assembled. The first assembly assembly is arranged on the conveying belt assembly along the Y-axis direction. The first workbench and the second workbench are arranged on the two sides of the first assembly assembly along the Y-axis direction. The transformer core rapid assembly system and the assembly method thereof are characterized in that the conveying belt assembly and the X / Y / Z-axis moving unit are cooperated to realize the automatic and rapid clamping and sleeving of the insulating paper and the winding, the problem of low efficiency of traditional manual assembly is solved, high-precision assembly operation is realized, and full automation of the assembly process is realized.

Description

Technical Field

[0001] This invention belongs to the field of transformer core processing, and specifically relates to a rapid assembly system for transformer cores and its assembly method. Background Technology

[0002] With the rapid development of new energy, high-end equipment manufacturing and other fields, 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; the production capacity bottleneck of manual assembly is becoming increasingly prominent.

[0003] In the field of transformer core manufacturing, existing systems often suffer from limitations such as limited functionality and insufficient coordination. For example, traditional conveying devices can only achieve linear transport of workpieces, cannot precisely connect with assembly mechanisms, and are difficult to adapt to spatial posture adjustments during insulation paper splicing. Although some equipment is equipped with vision inspection modules, it can only identify the presence or absence of workpieces and cannot collect position coordinates in real time and feed them back to the control system, resulting in the accumulation of assembly errors.

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

[0005] To address one or more of the above-mentioned defects or improvement needs in the existing technology, this invention provides a transformer core rapid assembly system and its assembly method. Through the coordinated operation of a conveyor belt assembly and an X / Y / Z axis moving unit, it achieves automated and rapid clamping and connection of insulating paper and windings, solving the problem of low efficiency in traditional manual assembly. Simultaneously, 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 grippers, achieving high-precision assembly operations, reducing manual intervention, and realizing full automation of the assembly process.

[0006] To achieve the above objectives, the present invention provides a rapid assembly system for transformer cores, comprising a conveyor belt assembly, a jig assembly, a first assembly assembly, a first workbench, and a second workbench.

[0007] The conveyor belt assembly is arranged along the X-axis direction, and the jig assembly is arranged on the conveyor belt assembly for carrying the lower yoke to be assembled; the first assembly assembly is straddling the conveyor belt assembly along the Y-axis direction.

[0008] The first assembly includes two support structures, which are respectively disposed on both sides of the conveyor belt assembly in the Y-axis direction; an X-axis moving unit is provided on the support, and a Y-axis moving module is provided between the two X-axis moving units; two sliders are spaced apart along the X-axis direction on the Y-axis moving module, each slider is provided with a Z-axis moving unit, and a gripper is provided in the telescopic unit of the Z-axis moving module; and the movement directions of the two grippers are opposite.

[0009] The first workbench and the second workbench are respectively located on both sides of the first assembly assembly in the Y-axis direction. The first workbench and the second workbench are respectively used to place the insulating paper and the winding structure to be assembled.

[0010] Meanwhile, a first detection camera is provided below each slider to collect image data and position information of the lower yoke, and to collect image data and position information of the workpiece to be assembled on the worktable when the gripper moves above the first or second worktable with the X-axis moving unit, the Y-axis moving unit and the Z-axis moving unit.

[0011] As a further improvement of the present invention, a second assembly assembly is also included, which is straddling the conveyor belt assembly along the Y-axis direction and spaced apart from the first assembly assembly in the X-axis direction.

[0012] It includes a frame and two first telescopic units, a second telescopic unit, and a third telescopic unit located on opposite sides inside the frame;

[0013] The first telescopic unit is arranged along the Y-axis, the second telescopic unit is arranged along the X-axis on the telescopic end of the first telescopic unit, and the third telescopic unit is arranged on the movable end of the second telescopic unit.

[0014] As a further improvement of the present invention, a pressure block is also provided on the telescopic end of the third telescopic unit for pressing the upper yoke onto the lower yoke.

[0015] As a further improvement of the present invention, a second detection camera is also provided at the top of the inner cavity of the frame for acquiring image data of the lower yoke located at the bottom of the frame.

[0016] As a further improvement of the present invention, the fixture assembly includes a carrier plate and a clamping structure; the clamping structure is disposed on the linear module and is used to clamp and limit the lower yoke.

[0017] 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 make fine adjustments along the X-axis direction.

[0018] As a further improvement of the present invention, an infrared receiver is also provided on the carrier plate;

[0019] Accordingly, an infrared transmitter is provided on the frame, which is communicatively connected to the infrared receiver and is used to locate the position of the carrier plate.

[0020] As a further improvement of the present invention, a data processing module is also included, 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 controlling the first assembly component, the second assembly component, and the conveyor belt component to operate in coordination according to the image data acquisition location information.

[0021] Based on this, the present invention also provides a rapid assembly method for transformer cores, which utilizes the aforementioned rapid assembly system. This method includes the following steps:

[0022] The iron core yoke is assembled onto the fixture assembly, and the fixture assembly is assembled onto the conveyor belt assembly;

[0023] The conveyor belt transports the jig assembly loaded with the lower yoke to the position of the first assembly assembly;

[0024] The first assembly component drives the gripper to move through the X-axis moving unit, Y-axis moving unit and Z-axis moving unit. It first performs the gripping operation on the insulating paper, and then grips the corresponding number of insulating papers according to the number of vertical core columns of the lower yoke, and then attaches the insulator to the vertical core columns of the lower yoke.

[0025] Next, adjust the position of the lower yoke in the X-axis direction, use the jaws on the other side to clamp the corresponding number of coil windings, and assemble them onto the vertical core of the lower yoke.

[0026] Complete the assembly of the lower yoke.

[0027] The aforementioned improved technical features can be combined with each other as long as they do not conflict with each other.

[0028] In summary, the beneficial effects of the above-described technical solutions conceived by this invention compared with the prior art include:

[0029] The transformer core rapid assembly system and its assembly method of the present invention achieve automated and rapid clamping and splicing of insulating paper and winding through the coordinated cooperation of conveyor belt assembly and X / Y / Z axis moving unit, solving the problem of low efficiency of traditional manual assembly; at the same time, with the help of a first detection camera and data processing module, the workpiece position information is accurately collected and the movement of the gripper is controlled to achieve high-precision assembly operation, reduce manual intervention, and realize the full automation of the assembly process. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the overall three-dimensional structure of the transformer core rapid assembly system in an embodiment of the present invention;

[0031] Figure 2 yes Figure 1 A schematic diagram of the overall three-dimensional structure from another perspective;

[0032] Figure 3 This is a schematic diagram of the overall structure of the first assembly component in the transformer core rapid assembly system of this invention.

[0033] Figure 4 yes Figure 3 A schematic diagram of the overall structure from another perspective;

[0034] Figure 5 This is a schematic diagram of the overall structure of the second assembly component in the transformer core rapid assembly system of this invention.

[0035] Figure 6 This is a schematic diagram of the overall structure of the fixture assembly in the transformer core rapid assembly system of this invention.

[0036] In all the accompanying drawings, the same reference numerals denote the same technical features, specifically:

[0037] 100. Conveyor Belt Components

[0038] 200. Fixture assembly; 201. Carrier plate; 202. Linear module; 203. Clamping structure;

[0039] 300. Lower yoke;

[0040] 400. First assembly component; 401. Support bracket; 402. X-axis moving unit; 403. Y-axis moving unit; 404. Z-axis moving unit; 405. Gripper; 406. First detection camera;

[0041] 500. Second assembly component; 501. Frame; 502. First telescopic unit; 503. Second telescopic unit; 504. Third telescopic unit; 505. Second detection camera;

[0042] 600. First workbench; 601. Insulating paper;

[0043] 700. Second worktable; 602. Winding structure. Detailed Implementation

[0044] 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.

[0045] It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, the technical features involved in the various embodiments of the invention described below can be combined with each other as long as they do not conflict with each other.

[0046] Please see Figures 1-6 The transformer core rapid assembly system in the preferred embodiment of the present invention specifically includes a conveyor belt assembly 100, a jig assembly 200, a first assembly assembly 400, a first workbench 600, and a second workbench 700. The conveyor belt assembly 100 is arranged along the X-axis, while the jig assembly 200 is arranged on the conveyor belt assembly 100 to support the lower yoke 300 to be assembled. The first assembly assembly 400 spans the conveyor belt assembly 100 along the Y-axis. The first assembly assembly 400 includes two support structures 401, which are respectively arranged on the conveyor belt assembly 100 along the Y-axis. The first assembly assembly 400 is located on both sides of the first assembly assembly 400 in the Y-axis direction. 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. Two sliders are arranged at intervals along the X-axis direction on the Y-axis moving module. Each slider is provided with a Z-axis moving unit 404, and a gripper 405 is provided on the telescopic unit of the Z-axis moving module. The two grippers 405 move in opposite directions. The first worktable 600 and the second worktable 700 are respectively located on both sides of the first assembly assembly 400 in the Y-axis direction. The first worktable 600 and the second worktable 700 are used to place the insulating paper 601 and the winding structure 602 to be assembled, respectively. At the same time, a first detection camera 406 is provided below each slider to collect image data and position information of the lower yoke 300. When the gripper 405 moves with the X-axis moving unit 402, the Y-axis moving unit 403 and the Z-axis moving unit 404 to the top of the first worktable 600 or the second worktable 700, it collects image data and position information of the workpiece to be assembled on the worktable.

[0047] More specifically, the rapid assembly system in the preferred embodiment of the present invention further includes a second assembly component 500, which is straddling the conveyor belt assembly 100 along the Y-axis direction and 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 inside the frame 501; wherein, the first telescopic unit 502 is arranged along the Y-axis direction, 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.

[0048] Furthermore, a pressure block is also provided on the telescopic end of the third telescopic unit 504 to press the upper yoke onto the lower yoke 300. At the same time, a second detection camera 505 is also provided on the top of the inner cavity of the frame 501 to collect image data of the lower yoke 300 located at the bottom of the frame 501.

[0049] In 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 at the top monitors the position of the lower yoke 300 in real time. Through multi-axis linkage, the upper yoke is precisely pressed to the lower yoke 300 to form a closed magnetic circuit, replacing the traditional manual pressing operation, ensuring that the air gap of the magnetic circuit is evenly distributed and improving the electromagnetic performance of the iron core.

[0050] More specifically, the jig assembly 200 includes a carrier plate 201 and a clamping structure 203; the clamping structure 203 is disposed on the linear module 202 for clamping and limiting the lower yoke 300. More preferably, the linear module 202 is disposed on the carrier plate 201 along the X-axis direction, and the clamping structure 203 is disposed on the linear module 202 for driving the linear module 202 to make fine adjustments along the X-axis direction.

[0051] Meanwhile, an infrared receiver is also installed on the carrier plate 201; correspondingly, an infrared transmitter is installed on the frame 501, which is communicatively connected to the infrared receiver and used to position the carrier plate 201. The fixture assembly 200, through the cooperation of the linear module 202 on the carrier plate 201 and the clamping structure 203, can adjust the clamping position according to the iron core specifications. Combined with the positioning calibration of the infrared receiver and the transmitter of the frame 501, it can achieve adaptive clamping and precise positioning of iron cores with different numbers of core columns, solve the problem of time-consuming changeover of traditional fixed fixtures, and enhance the flexible production capability of the production line.

[0052] In addition, the preferred embodiment of the present invention also includes a data processing module, which is communicatively connected to the first detection camera 406 and the second detection camera 505, respectively, for receiving image data collected by the first detection camera 406 and the second detection camera 505, and controlling the first assembly component 400, the second assembly component 500, and the conveyor belt component 100 to work together according to the image data acquisition location information.

[0053] In practical use, the conveyor belt assembly 100 is set along the X-axis, and the fixture assembly 200 is mounted on the conveyor belt. Its carrier plate 201 drives the clamping structure 203 to make fine adjustments along the X-axis through the linear module 202. With the communication positioning between the infrared receiver and the infrared transmitter of the frame 501, the lower yoke 300 is stably clamped and its position is calibrated, solving the offset problem caused by traditional manual handling and providing a precise benchmark for subsequent assembly. The first assembly assembly 400 is straddling both sides of the conveyor belt along the Y-axis. It forms a three-axis linkage structure through the X-axis moving unit on the bracket 401, the Y-axis moving module, and the Z-axis moving unit on the slider. The gripper 405 moves in the opposite direction under the drive of the slider to synchronously grab the workpiece. The first detection camera 406 under the slider collects image data of the lower yoke 300 and the workpiece on the worktable in real time. After the data processing module calculates the data, it controls the three-axis linkage to realize the precise splicing of the insulating paper 601 according to the number of core columns and the automated assembly of the winding. The robotic arm replaces manual operation, which significantly improves the assembly efficiency and consistency.

[0054] The data processing module, together with the first and second detection cameras 505, forms a closed-loop control system. It receives image data in real time and calculates the workpiece position information. It synchronously controls the conveyor belt assembly 100, the first assembly assembly 400, and the second assembly assembly 500 to work together. The entire process is automated, from the splicing of the insulating paper 601 and the assembly of the winding to the pressing of the upper yoke. This avoids the accumulation of human operation errors and improves the assembly accuracy and system stability.

[0055] Based on this, the present invention also provides a rapid assembly method for transformer cores, which utilizes the aforementioned rapid assembly system. The method includes the following steps: assembling the upper yoke of the core onto a jig assembly 200, and assembling the jig assembly 200 onto a conveyor belt assembly 100; the conveyor belt transports the jig assembly 200, carrying the lower yoke 300, to the position of the first assembly assembly 400; the first assembly assembly 400 drives the grippers 405 to move via an X-axis moving unit 402, a Y-axis moving unit 403, and a Z-axis moving unit 404, first gripping the insulating paper 601, then gripping a corresponding number of insulating papers 601 according to the number of vertical cores of the lower yoke 300, and attaching the insulators to the vertical cores of the lower yoke 300; next, adjusting the position of the lower yoke 300 in the X-axis direction, using the grippers 405 on the other side to grip a corresponding number of coil windings, and assembling them onto the vertical cores of the lower yoke 300; thus completing the assembly of the lower yoke 300.

[0056] The assembly method relies on the above system. First, the lower yoke 300 is fixed to the fixture and transported to the assembly station by the conveyor belt. The first assembly component 400 completes the connection of the insulating paper 601 and the winding assembly through the three-axis linkage gripper 405. Subsequently, the second assembly component 500 automatically presses the upper yoke. Each process achieves precise coordination 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 core assembly.

[0057] Those skilled in the art will readily understand 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 within the scope of protection of the present invention.

Claims

1. A rapid assembly system for transformer cores, characterized in that, It includes a conveyor belt assembly, a jig assembly and a first assembly assembly, as well as a first worktable and a second worktable; The conveyor belt assembly is arranged along the X-axis direction, and the jig assembly is arranged on the conveyor belt assembly for carrying the lower yoke to be assembled; the first assembly assembly is straddling the conveyor belt assembly along the Y-axis direction. The first assembly includes two support structures, which are respectively disposed on both sides of the conveyor belt assembly in the Y-axis direction; an X-axis moving unit is provided on the support, and a Y-axis moving unit is provided between the two X-axis moving units; two sliders are spaced apart along the X-axis direction on the Y-axis moving unit, and a Z-axis moving unit is provided on each slider, with a gripper provided in the telescopic unit of the Z-axis moving unit; and the movement directions of the two grippers are opposite. The first workbench and the second workbench are respectively located on both sides of the first assembly assembly in the Y-axis direction. The first workbench and the second workbench are respectively used to place the insulating paper and the winding structure to be assembled. Meanwhile, a first detection camera is provided below each slider to collect image data and position information of the lower yoke, and to collect image data and position information of the workpiece to be assembled on the worktable when the gripper moves above the first worktable or the second worktable with the X-axis moving unit, the Y-axis moving unit and the Z-axis moving unit. It also includes a second assembly component, which is straddling the conveyor belt assembly along the Y-axis and spaced apart from the first assembly component along the X-axis; it includes a frame and two first telescopic units, a second telescopic unit and a third telescopic unit located on opposite sides inside the frame; wherein, the first telescopic unit is arranged along the Y-axis, the second telescopic unit is arranged along the X-axis on the telescopic end of the first telescopic unit, and the third telescopic unit is arranged on the movable end of the second telescopic unit.

2. The transformer core rapid assembly system according to claim 1, characterized in that, A pressure block is also provided on the telescopic end of the third telescopic unit to press the upper yoke onto the lower yoke.

3. The transformer core rapid assembly system according to claim 1, characterized in that, A second detection camera is also installed at the top of the inner cavity of the frame, which is used to collect image data of the lower yoke located at the bottom of the frame.

4. The transformer core rapid assembly system according to any one of claims 1 to 3, characterized in that, The fixture assembly includes a carrier plate and a clamping structure; 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 clamping and limiting the lower yoke.

5. The transformer core rapid assembly system according to claim 4, characterized in that, An infrared receiver is also provided on the carrier plate; Accordingly, an infrared transmitter is provided on the frame, which is communicatively connected to the infrared receiver and used to locate the position of the carrier plate.

6. The transformer core rapid assembly system according to claim 4, characterized in that, 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 controlling the first assembly component, the second assembly component, and the conveyor belt component to work together according to the image data acquisition location information.

7. A rapid assembly method for a transformer core, characterized in that, It is achieved using the rapid assembly system according to any one of claims 1 to 6, and the method includes the following steps: The iron core yoke is assembled onto the fixture assembly, and the fixture assembly is assembled onto the conveyor belt assembly; The conveyor belt transports the jig assembly loaded with the lower yoke to the position of the first assembly assembly; The first assembly component drives the gripper to move through the X-axis moving unit, Y-axis moving unit and Z-axis moving unit. It first performs the gripping operation on the insulating paper, and then grips the corresponding number of insulating papers according to the number of vertical core columns of the lower yoke, and then attaches the insulator to the vertical core columns of the lower yoke. Next, adjust the position of the lower yoke in the X-axis direction, use the jaws on the other side to clamp the corresponding number of coil windings, and assemble them onto the vertical core of the lower yoke. Complete the assembly of the lower yoke.

Images