Parallel reactor iron core stacking method

Abstract

The invention relates to the technical field of electric reactor manufacturing, in particular to a parallel type electric reactor iron core stacking method which comprises the steps of positioning structure preprocessing, silicon steel sheet precise stacking, special glue layered brushing, fastening, binding and curing full-process optimization, positioning precision closed-loop control introduction, glue solution ratio dynamic adjustment and curing time intelligent prediction algorithm introduction. In order to solve the problems of high operation intensity, long production period and difficult quality control caused by brushing resin piece by piece in the traditional process, the method comprises the following specific steps: forming phi 16 positioning holes in silicon steel sheets, realizing glue-free pre-stacking through a positioning rod, brushing twice by using J-7II double-component special glue, standing and permeating, and predicting curing time according to temperature and humidity after fastening an assembly clamp. And finally, fixing by using a PET binding tape. The iron core stacking qualification rate can be greatly improved, the production period is shortened, the comprehensive cost is reduced, and the method is suitable for industrial batch production.

Description

[0001] The present application relates to the technical field of electric reactor manufacturing, and particularly relates to a parallel electric reactor core stacking method. BACKGROUND

[0002] The parallel electric reactor is an indispensable key equipment in the power system, mainly used for compensating capacitive reactive power, inhibiting the rise of grid voltage, improving power quality, and widely applied to high-voltage transmission lines, power substations and other scenes. The core is the magnetic circuit core of the parallel electric reactor, and the manufacturing precision of the core directly determines the loss, noise level, operation stability and service life of the electric reactor. Therefore, the core stacking process is one of the core links in the production of the electric reactor. SUMMARY

[0003] At present, the manufacturing of the parallel electric reactor core usually adopts the process of brushing a layer of resin every time a silicon steel sheet is stacked until the stacking is completed, and then assembling the clamping piece, screw rod and binding the PET polyester binding belt. The traditional process has obvious defects, the operation process is complicated, the integrity between the laminated sheets and the stacking quality are difficult to accurately control, the production cycle is long, in addition, the brushed resin needs to be dried in the furnace, which further increases the production energy consumption and time, resulting in high production cost.

[0004] In view of the defects of the prior art, the present application aims to provide a new parallel electric reactor core stacking method, which aims to solve the problems of high work intensity, complex process, long production cycle and high cost of the existing process.

[0005] A new parallel electric reactor core stacking method, comprising the following steps:

[0006] S1: Preprocessing the positioning structure, two positioning round holes are opened on the parallel electric reactor core silicon steel sheet to be stacked, the design aperture of the positioning round hole is , the design center distance of the two positioning round holes is set according to the product drawing, the actual aperture deviation of the positioning round hole is detected after processing , the actual center distance deviation is , , the aperture is qualified, otherwise it is judged as a waste sheet and needs to be reprocessed, , the center distance is qualified, if the deviation is exceeded, the axis positioning parameter of the numerical control punch press needs to be adjusted, and the punching is re-tried;

[0007] Wherein is the design aperture, is the actual aperture, is the design center distance, is the actual center distance;

[0008] S2: Silicon steel sheet stacking operation, the cut silicon steel sheet is matched with the positioning rod and the positioning hole, and is stacked layer by layer according to the stacking order and the number of layers specified in the product drawing. During the stacking process, the single silicon steel sheet is not coated with resin. After every 100 silicon steel sheets are stacked, the stacking flatness is detected , the requirement , if the tolerance is exceeded, the positioning rod verticality needs to be adjusted or the deformed silicon steel sheet needs to be replaced. The stacking flatness δ is calculated by multi-point sampling. Five measurement points are uniformly selected on the surface of the core, and the gap value of each point from the reference level is recorded , the flatness deviation formula:

[0009]

[0010] wherein, is the measurement span, i.e. the width of 100 silicon steel sheets, is the maximum value of the gap of all measurement points, is the minimum value of the gap of all measurement points,

[0011] After stacking is completed, the actual stacking height deviation is detected , the requirement ,

[0012] wherein, is the design stacking height, is the actual stacking height;

[0013] S3: Special glue preparation process: select transformer silicon steel sheet end face double-component special glue, and mix according to the weight ratio of A group: B group = 2:1. Through the proportioning accuracy calculation function, the actual proportioning deviation rate is calculated:

[0014] ,

[0015] wherein, is the weight of A group, is the weight of B group, is the theoretical proportioning;

[0016] so that the initial viscosity of the mixed glue liquid , the glue liquid viscosity calculation formula:

[0017]

[0018] the proportioning deviation rate ;

[0019] S4: Special glue brushing, the stacked core and all silicon steel sheet cut surfaces are brushed for the first time, and brushed for the second time after standing for 10 minutes, is discarded;​

[0020] wherein is the viscosity after the modulation minutes, wherein is the time after the modulation in min;

[0021] S5: fastening and binding treatment, within 10 minutes after the completion of the secondary coating, assembling the core clamp and fixture, and tightening the clamp bolt according to the preset torque , the torque deviation wherein is the actual fastening torque, the core is placed in an environment with a temperature of 20-28°C and a relative humidity of ≤65% for curing, and a J-7II glue curing time prediction model is established based on the environmental temperature and humidity:

[0022] ;

[0023] predicted curing time wherein is the environmental temperature, is the environmental relative humidity, after curing, the fixture is removed and the PET polyester binding belt is cross-bound, and the actual tension of the binding belt is required .

[0024] Further: in step S1, after the positioning round hole is processed, the iron filings in the round hole are blown clean by compressed air, and a special go-no-go gauge is used to detect the smoothness of the round hole.

[0025] Further: in step S2, the material of the positioning rod is 45# steel and the surface is chromium plated, the diameter of the positioning rod is and the length is ≥ ;

[0026] When stacking, the verticality of the core is calibrated every 50 silicon steel sheets using a right-angle ruler, and three measurement points are uniformly selected along the stacking height direction of the silicon steel sheets, i.e., the bottom, the middle, and the top, so that the verticality deviation is ≤0.1mm / 100mm, and the verticality deviation calculation formula is:

[0027] ,

[0028] wherein is the maximum gap value in the three measurement points, is the stacking height corresponding to the measurement point.

[0029] Further: in step S3, the glue solution is modulated using an electric mixer, the stirring speed is 300-500r / min, the stirring time is 5-8 minutes until the glue solution is free of particles and stratification, and the total thickness of the coating layers of the first coating and the second coating is 0.2-0.3mm.​​

[0030] Further: in step S4, the bolt of the clamp is tightened by using the symmetrical fastening method, that is, the bolt is first tightened at an angle, and then the force is uniformly increased step by step, and the judgment standard for solidification completion is that the Shore hardness of the glue layer is greater than or equal to 60D, and the silicon steel sheet peeling force is greater than or equal to 1.5MPa.

[0031] Further: the wire drawing frame is adapted to the wire core diameter range of 0.5-10mm, and the initial diameter range of the wire disc is 300-800mm.

[0032] Further: in step S1, if the maximum deviation of the actual measurement of the continuous three silicon steel sheets Or , the numerical control punch parameter compensation is triggered, and the compensation amount , wherein is the maximum deviation of the actual measurement, is the upper limit of the deviation tolerance.

[0033] Further: in step S3, if the actual proportioning deviation rate of the glue solution , the deviation side glue solution needs to be added, If the A group is added, the added amount , , the B group is added, and the added amount ;

[0034] Wherein is the actual A group mass, is the actual B group mass.

[0035] Further: in step S4, the width of the PET polyester binding tape is 15mm, the thickness is 0.8mm, and one binding is made every 100mm along the height direction of the iron core during binding, the adjacent two binding tapes are crossed at 45°, the binding tape joint is welded by hot melting, and the welding length is greater than or equal to 20mm.

[0036] The present application has the following beneficial effects:

[0037] 1. The two redundant processes of "resin brushing piece by piece" and "furnace drying solidification" in the traditional process are cancelled, the operation steps are directly reduced, the dependence on repeated brushing and high-temperature drying is eliminated, the dependence on the skills of the operating personnel is reduced through the standardized positioning stacking and layered brushing process, thereby the labor intensity is reduced, the number of operating personnel for a single device can be reduced from 3-5 people in the traditional process to 2 people, and the operation convenience is greatly improved.

[0038] 2. Adopting the double-reference control structure of "positioning hole + positioning rod", a precise stacking positioning system is established, so that the flatness deviation of the core stacking is strictly controlled to be ≤0.1 mm / m, and the height deviation is ≤0.5 mm, the misalignment and inclination caused by traditional manual alignment are solved, the quality qualified rate is greatly improved, the rework loss caused by the non-standard precision is reduced, and the uniformity of the magnetic circuit distribution is ensured.

[0039] 3. Through precise control by curing time algorithm, invalid waiting in the traditional process is avoided, the production cycle is shortened, the special glue layering brushing and proportioning precision control technology is improved, the glue utilization rate is greatly improved, compared with the traditional resin brushing, the material waste is reduced, the process is simplified, the efficiency is improved, and the material saving forms a synergistic cooperation, so that the comprehensive production cost is reduced.

[0040] 4. The drying link into the furnace is cancelled, the high energy consumption caused by high temperature drying is completely avoided, and the volatile organic emissions in the traditional resin brushing process are reduced, the green production standard is achieved from the aspects of energy consumption and environmental protection, the application of the environment-friendly special glue makes the disposal of waste glue more convenient, there is no secondary pollution risk, and it is completely suitable for the environmental protection requirements of modern large-scale industrial production of electrical equipment. BRIEF DESCRIPTION OF DRAWINGS

[0041] Figure 1 It is a flowchart of a parallel reactor core stacking method. DETAILED DESCRIPTION

[0042] The application will be further described below in conjunction with specific embodiments. Obviously, the described embodiments are only part of the embodiments of the application, not all the embodiments. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor belong to the scope of protection of the application.

[0043] A parallel reactor core stacking method, comprising the following specific implementation steps:

[0044] 1. Positioning structure pretreatment

[0045] (1) Positioning hole processing parameter setting: according to the product drawing, the design hole diameter d0 and the design center distance L0 of the positioning circular hole are determined, the numerical control punch is debugged, the shaft positioning parameters are input into the system, the thickness matched silicon steel sheet to be processed is selected and fixed on the punch workbench, the clamping deviation is ensured to be ≤0.02 mm, the two-way reference can be established by the double circular hole positioning, the rotation deviation of single hole positioning is avoided, the rolling direction of the silicon steel sheet is consistent to optimize the symmetry of the magnetic circuit, the clamping precision controls the subsequent hole processing precision, and the processing reference deviation is controlled from the source to provide the front guarantee for the stacking precision;

[0046] (2) Positioning hole processing and single hole quality detection: start the numerical control punch to complete double positioning hole processing, randomly select 1 piece for detection every 10 pieces, measure the actual hole diameter with a digital micrometer , ensure , measure the actual center distance with a universal tool microscope , ensure , mark the out-of-tolerance pieces as waste pieces, stop adjusting the punch shaft positioning parameters when out of tolerance, and test 3 pieces before mass production, which can be qualified after passing the test, the hole diameter deviation is controlled within the allowable range of the stacking clearance, avoiding loose misalignment or tight extrusion of the positioning rod and the hole, and the center distance precision directly determines the uniformity of the magnetic circuit, and the out-of-tolerance will cause local magnetic resistance mutation, which improves the single hole processing qualification rate and avoids unqualified pieces flowing into the stacking link to cause rework;

[0047] (3) Continuous out-of-tolerance parameter compensation: if 3 consecutive pieces are out of tolerance or , record the maximum measured deviation and the upper limit of tolerance , calculate the compensation amount according to , input the punch system to complete parameter correction, and continuously out-of-tolerance is determined as equipment system deviation, dynamic compensation can eliminate equipment cumulative error, and improve the stability of punch processing precision;

[0048] (4) Positioning hole cleaning and smoothness verification: use 0.3~0.5MPa compressed air to blow the positioning hole for 3~5 seconds, remove iron filings in the hole, select a special go-no-go gauge matching the specification, the go gauge should smoothly pass through the round hole, and the no-go gauge should not enter the hole, and unqualified pieces are removed, iron filings residue will cause uneven gap between the positioning rod and the hole, causing stacking misalignment, and go-no-go gauge detection can directly verify whether the hole diameter is within the qualified range;

[0049] 2. Silicon steel sheet stacking operation

[0050] (1) Positioning rod installation and inspection: select 45# steel chromium plated positioning rod, diameter 15.9±0.05mm, length≥H0+50mm, after detecting the perpendicularity of the positioning rod with a dial gauge ≤0.02mm / m, fix it on the reference seat of the stacking platform, ensure the radial runout ≤0.01mm, 45# steel ensures rigidity, chromium plating improves surface hardness and wear resistance, and the perpendicularity of the positioning rod provides accurate vertical reference for stacking, which improves the durability of the positioning rod by 3 times, avoiding the increase of gap caused by long-term wear.

[0051] (2) Layer-by-layer stacking and verticality calibration: The pre-treated silicon steel sheets are fitted with positioning rods through positioning holes and stacked layer by layer according to the stacking order in the product drawings. When stacking, gently push the silicon steel sheets to ensure they are in contact with the positioning rods; after stacking 50 sheets, use a grade 0 cast iron right-angle ruler for calibration: the long side is close to the positioning rod, and the short side is aligned with the edge of the silicon steel sheet. Use a feeler gauge to measure the gap g at three points: 50mm from the bottom of the platform, 25 sheets high in the middle, and 50 sheets high in the top. Calculate the verticality deviation to ensure α≤0.1mm / 100mm. If the deviation exceeds the limit, fine-tune the verticality of the positioning rod or replace the deformed silicon steel sheet. The 0.05~0.1mm fit gap between the positioning rod and the round hole takes into account both guidance and assembly. 50 pieces is the critical accumulation node for deviation. High-frequency calibration can avoid the superposition of deviations. Three-point measurement covers the entire accumulation process, captures the tilt trend, improves the verticality deviation control rate, avoids later magnetic circuit deviation, and reduces reactor operating losses.

[0052] (3) Flatness and height inspection: For every 100 pieces stacked, place the reference straightedge against the core surface, select 5 measuring points at the four corners and the center, and use a 0.001mm precision feeler gauge to measure the gaps h1~h5, according to... Calculate the flatness to ensure δ≤0.1mm / m; after the full stacking is completed, measure the actual height H using a digital height gauge. ant Ensure |H ant -H0|≤0.5mm, 5-point measurement covers areas prone to protrusion / depression, avoiding the randomness of single-point measurement. Flatness affects the assembly gap between the iron core and the coil, and height deviation affects magnetic reluctance and capacitance.

[0053] 3. Special adhesive preparation process

[0054] (1) Preparation of adhesive and tools: Select J-7Ⅱ transformer silicon steel sheet end face two-component special adhesive. Check that component A (base adhesive) is milky white uniform liquid and component B (curing agent) is light yellow transparent liquid, without impurities and stratification; prepare an electronic scale with an accuracy of 0.01g, an electric stirrer of 300~500r / min, and a stainless steel mixing tank with polished inner wall. Clean the mixing tank with anhydrous ethanol and let it dry. The appearance of the liquid can be used to preliminarily judge whether it has deteriorated. Clean the tools to avoid impurities affecting the compatibility of the adhesive. Eliminate the hidden dangers of adhesive and tools in advance to ensure the preparation quality.

[0055] (2) Accurate weighing and proportion correction: Weigh according to the weight ratio of Group A:Group B = 2:1, and record m. a (Group A), m β (Group B), according to Calculate the deviation rate; if η > 2%, then m a / m β When <2, add Δm. a =2m β -m a Group A, m a / m β When t = 2, additional Δm β = m a / 2-m β Group B, after adding, re-weighing to confirm η≤2%, two components crosslinking reaction according to stoichiometric ratio, deviation beyond limit, crosslinking imbalance will lead to abnormal viscosity or bonding failure, accurate addition can restore the theoretical ratio, avoid glue waste, and ensure bonding strength.

[0056] (3) Stirring and viscosity detection: pour group A into the stirring tank, pre-stir at 300 r / min for 2 minutes; after adding group B, stir at 400-500 r / min for 5-8 minutes until the glue is uniform and there are no particles; use NDJ-8S rotary viscometer to measure the initial viscosity μ(0), ensure 200-300 mPa·s, if not qualified, adjust group A and group B proportionally, gradient stirring to avoid air bubbles and ensure uniform mixing, 200-300 mPa·s viscosity takes into account the flowability and permeability, providing protection for brushing quality.

[0057] 4. Special glue brushing operation

[0058] (1) Preparation before brushing: Place the qualified stacked core in an environment of 20-25°C and humidity ≤60%, blow the silicon steel sheet cut surface clean of iron filings and dust with 0.3 MPa compressed air; select a 15-20 mm bristle wool brush or a 1.5-2.0 mm nozzle pneumatic spray gun, check for no loose hair or blockage, environmental temperature and humidity affect the glue curing rate, clean the surface to avoid impurities affecting bonding, reduce bonding defects, and improve the bonding force of the glue layer and silicon steel sheet.

[0059] (2) Layered brushing and standing: Brush evenly along the cut surface perpendicular to the stacking direction for the first time, measure the thickness with a coating thickness gauge to ensure no missed brushing, 0.1-0.2 mm; stand for 10±1 minutes before the second brushing, focus on filling the gap between layers, total thickness control 0.2-0.3 mm; measure the glue viscosity μ(t) every 30 minutes during brushing, if t≥120 min or μ(t)>400 mPa·s, discard the glue, the first brushing forms a basic bonding layer, standing for 10 minutes utilizes capillary action to penetrate between layers, the second brushing supplements the blind area, total thickness takes into account strength and permeability, glue overage leads to increased crosslinking degree, which cannot be evenly brushed,

[0060] Glue utilization rate is improved, coating thickness consistency is ±0.02 mm, bonding failure risk is reduced, and the step of brushing each piece is cancelled, reducing labor intensity.

[0061] 5. Fastening and binding

[0062] (1) Clamping assembly and symmetrical fastening: within 10 minutes after secondary coating, assemble the core clamps and fixtures, and use the torque wrench to operate according to the symmetrical fastening method. First, tighten the four reference bolts diagonally to 50% of the preset torque F0, and then gradually and evenly increase the force to F0, ensuring that The remaining bolts are fastened according to the same process. When the adhesive is not cured, fixing the shape can prevent deformation. Symmetrical fastening offsets the core deformation and avoids unilateral force tilting.

[0063] (2) Environmental curing and quality determination: place the core in an environment of 20-28°C and humidity ≤65%, and follow to predict the curing time. After reaching the time, use a Shore hardness tester to measure the adhesive layer hardness ≥60D, and use a tensile testing machine to measure the silicon steel sheet peel strength ≥1.5MPa. After determining that the curing is qualified, remove the fixtures. Temperature and humidity affect the crosslinking reaction rate, and the model can accurately control the curing time. Hardness reflects the degree of curing, and peel strength directly verifies the bonding performance.

[0064] (3) PET binding and finished product inspection: select 15mm×0.8mm PET polyester binding tape, bind one row every 100mm along the height of the core, and the adjacent two rows are 45° intersected. The joints are welded with a hot melt welding machine, and the welding length is ≥20mm, ensuring that the binding tension is ≥270N. Finally, detect the core radial circular runout ≤1mm to complete the finished product. Cross binding forms a net-like stress structure, and sufficient tension and welding length ensure joint strength.

[0065] Finally, it should be noted that the above-described only for the preferred embodiments of the present application, and not for limiting the present application, although the foregoing embodiments of the present application have been described in detail, for those skilled in the art, it still can be modified, or part of the technical features of the equivalent replacement, within the spirit and principles of the present application, any modification, equivalent replacement, improvement, etc., should be included within the scope of the present application.

Claims

1. A method for stacking iron cores of a parallel reactor, characterized in that, Includes the following steps: S1: Pre-treatment of the positioning structure: Two positioning circular holes are made on the silicon steel sheets of the parallel reactor core to be stacked. The designed diameter of the positioning circular holes is [missing information]. The center distance between the two positioning holes is set according to the product drawings. After machining, the actual diameter deviation of the positioning holes is checked. Actual center distance deviation , If the aperture is within acceptable limits, the piece is considered defective and needs to be reprocessed. The center distance is within acceptable limits; if it exceeds the tolerance, the CNC punching machine needs adjustment. Adjust the shaft positioning parameters and re-test the punch; in To design the aperture, This is the actual aperture. To design the center distance, This is the actual center distance; S2: Silicon steel sheet stacking operation. The cut silicon steel sheets are aligned with the positioning holes using positioning rods, and stacked layer by layer according to the stacking sequence and number of layers specified in the product drawings. No resin coating is applied to individual silicon steel sheets during the stacking process. The flatness of the stack is checked after every 100 silicon steel sheets are stacked. ,Require If the deviation exceeds the tolerance, the verticality of the positioning rod needs to be adjusted or the deformed silicon steel sheet needs to be replaced. Multi-point sampling is used to calculate the stacked flatness δ. Five measurement points are evenly selected on the core surface, and the gap values ​​between each point and the reference straightedge are recorded. Flatness deviation formula: in, To measure the span, that is, the width of 100 silicon steel sheets, The maximum value of the gap among all measurement points. The minimum value of the gap among all measurement points. After stacking, the actual stacking height deviation is detected. ,Require , ; in, To design the stacking height, This represents the actual stacking height; S3: Special adhesive preparation process: Selected The two-component special adhesive for the end face of transformer silicon steel sheets is prepared at a weight ratio of component A to component B of 2:

1. The actual mixing ratio deviation rate is calculated using a mixing accuracy calculation function. ， in, This refers to the weight of Group A. For the weight of group B, For theoretical proportions; The initial viscosity of the prepared adhesive solution Formula for calculating adhesive viscosity: Required proportion deviation rate ; S4: Apply the special adhesive to the stacked iron core and all cut surfaces of the silicon steel sheets. After standing for 10 minutes, apply the second coat. Discarded at the time; in After modulation Viscosity in minutes, ,in The modulated time is in minutes. S5: Fastening and binding treatment. Within 10 minutes after the second coat is applied, assemble the core clamps and fixtures, according to the preset torque. Tighten the clamp bolts. Required torque deviation ,in To determine the actual tightening torque, the iron core was placed in an environment with a temperature of 20~28℃ and a relative humidity of ≤65% for curing. Based on the ambient temperature and humidity, a prediction model for the curing time of J-7Ⅱ adhesive was established. ； Predicted curing time ,in For ambient temperature, To maintain the relative humidity of the environment, remove the clamps after curing, and then cross-tie with PET polyester cable ties, ensuring the actual tension of the cable ties is within acceptable limits. .

2. The method according to claim 1, characterized in that, In step S1, after the positioning hole is machined, the iron filings inside the hole are blown away with compressed air, and the unobstructedness of the hole is checked with a special go / no-go gauge.

3. The method according to claim 1, characterized in that, In step S2, the positioning rod is made of 45# steel with a chrome-plated surface, and the diameter of the positioning rod is [missing information]. , length ≥ ; During stacking, the verticality of the core is calibrated with a right-angle ruler every 50 silicon steel sheets. Three measurement points are evenly selected along the stacking height of the silicon steel sheets: the bottom, the middle, and the top, to ensure the verticality deviation is within acceptable limits. ≤0.1mm / 100mm, verticality deviation calculation formula: ， in The maximum gap value among the three measurement points. This represents the stacking height corresponding to the measurement point.

4. The method according to claim 1, characterized in that, In step S3, the adhesive solution is prepared using an electric stirrer at a speed of 300-500 r / min for 5-8 minutes until the adhesive solution is free of particles and stratification. The total thickness of the coating from the first and second coats is 0.2-0.3 mm.

5. The method according to claim 1, characterized in that, In step S4, the clamp bolts are tightened using a symmetrical tightening method, that is, the bolts are tightened diagonally first, and then the force is gradually and evenly applied. The criteria for determining the completion of curing are that the Shore hardness of the adhesive layer is ≥60D and the peel force of the silicon steel sheet is ≥1.5MPa.

6. The method according to claim 1, characterized in that, In step S1, if three consecutive silicon steel sheets... or Triggering CNC punch press parameter compensation, compensation amount ,in This represents the maximum measured deviation. This represents the upper limit of the deviation tolerance.

7. The method according to claim 1, characterized in that, In step S3, if the actual ratio deviation of the adhesive solution is... Additional adhesive solution needs to be added to the deviation side. Then supplement Group A, and supplement the amount. , Then add Group B, the amount to be added. ; in For the actual quality of Group A, This refers to the actual quality of Group B.

8. The method according to claim 1, characterized in that, In step S4, the PET polyester binding tape is 15mm wide and 0.8mm thick. When binding, one tape is tied every 100mm along the height of the iron core. Adjacent binding tapes cross at 45°. The binding tape joints are hot-melt welded, and the welding length is ≥20mm.

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