A method of assembling a roebel coil

Abstract

The present application relates to a kind of roebel assembly method, the assembly process of roebel coil is at least divided into sequentially executed wire welding pedal pruning process (P1) and lead tin upper copper tube process (P2);The process P1 includes silica gel tube pruning, circuit board welding and lead pruning;The process P2 includes silica gel tube pruning, enamel wire tin and copper tube crimping;Wherein, in the enamel wire tin step of the process P2, the length area of 1.0-1.5 cm of enamel wire root is set as tin-free zone, and tin is carried out to non-tin-free zone;Wherein, in the enamel wire tin step of the process P2, constant temperature welding platform is used, control welding temperature is 380±5 DEG C, control tin time is 2.0 seconds, by being divided into P1 and P2 two major processes in the complex assembly process, accurate quantification and regulation are carried out, the randomness of human operation is eliminated, the consistency of each product process is ensured, so that the uniformity and stability of product performance are guaranteed.

Description

Technical Field

[0001] This invention relates to the field of electrical measurement technology, and more specifically to a method for assembling a Rogowski coil. Background Technology

[0002] A Rogowski coil is a sensor that measures alternating current using the principle of electromagnetic induction. Due to its advantages such as no magnetic saturation, wide measurement range, and electrical isolation from the circuit being measured, it is widely used in power systems, industrial control, and other fields. The performance of a Rogowski coil, such as linearity, phase error, and temperature stability, largely depends on the consistency and precision of its manufacturing process.

[0003] Traditional Rogowski coil assembly relies heavily on the operator's experience and skills, which presents the following problems: 1. Poor consistency: Different personnel or the same personnel operating at different times make it difficult to accurately control process parameters (such as welding temperature, time, and assembly dimensions), resulting in inconsistent product performance and unstable yield.

[0004] 2. Reliability Risks: If the tinned area on the enameled wire extends to the root, thermal stress or flux penetration may cause wire damage or insulation degradation, affecting long-term reliability. Improper lead crimping and component assembly dimensions may lead to poor contact or insufficient structural strength.

[0005] 3. Difficulty in efficiency and quality control: The process steps and standards are not clear, making it difficult to effectively divide the process, standardize operations and monitor quality.

[0006] Therefore, there is an urgent need for a standardized and parameterized Rogowski coil assembly method and corresponding production line to improve product consistency, reliability and production efficiency. Summary of the Invention

[0007] The purpose of this invention is to overcome the defects in the prior art and provide a Rogowski coil assembly method.

[0008] To achieve the above objectives, the technical solution of the present invention is to design a Rogowski coil assembly method, which includes at least the following steps: The assembly process of Rogowski coils is divided into at least two sequential steps: wire bonding pedal trimming (P1) and lead soldering copper tube pressing (P2). The process P1 includes silicone tube trimming, circuit board soldering, and lead wire trimming. The process P2 includes silicone tube trimming, tinning of enameled wire leads, and copper tube crimping. In the tinning step of the enameled wire lead in process P2, a 1.0-1.5 cm length region at the root of the enameled wire lead is designated as a tin-free zone, and tinning is applied to the non-tin-free zone. In the tinning step of the enameled wire in process P2, a constant temperature soldering station is used to control the soldering temperature at 380±5℃ and the tinning time at 2.0 seconds.

[0009] A further preferred technical solution includes, before the circuit board soldering step in process P1, the following step: Using a dedicated spacing fixture, the assembly distance between the circuit board and the inner core face of the Rogowski coil enameled wire is controlled to be 1.5 ± 0.5 mm.

[0010] A further preferred technical solution is that, in the lead wire trimming step of process P1, the lead wire length is controlled to be no more than 1.5 mm.

[0011] In a further preferred embodiment, the method further includes the following steps: The temperature of the constant temperature welding station shall be calibrated regularly, with a calibration frequency of no less than twice per work shift.

[0012] A further preferred technical solution is to use a tin-dipping fixture with a height limiting block to set the tin-free zone at the root of the enameled wire lead.

[0013] In a further preferred embodiment, the special spacing fixture is a sheet gauge plate with a thickness of 1.5 mm.

[0014] In a further preferred embodiment, the method further includes a quality control step, which includes: The welding temperature and tinning time are regularly inspected and recorded. The assembly distance between the circuit board and the enameled wire core, and the length of the plastic coating at the lead crimping point are all inspected.

[0015] This invention provides a Rogowski coil assembly production line for implementing any of the methods described above, comprising: The first processing unit is used to perform the circuit board trimming process (P1). The second processing unit is used to perform the lead-on tin-copper tube pressing process (P2). The second processing unit includes: a constant temperature soldering station with a temperature set at 380±5℃, a timing device for controlling the tinning time to 2.0 seconds, and a limiting fixture for forming a tin-free zone at the root of the enameled wire lead.

[0016] The advantages and beneficial effects of this invention are as follows: 1. Process standardization and stability: By clearly dividing the complex assembly process into two major processes, P1 and P2, and precisely quantifying and specifying the key parameters (temperature 380±5℃, time 2.0 seconds, distance 1.5±0.5 mm, solder-free zone 1.0-1.5 cm) for each sub-step (such as tinning, soldering, and assembly), the arbitrariness of human operation is eliminated, ensuring the consistency of the process for each product, thereby guaranteeing the uniformity and stability of product performance.

[0017] 2. Enhanced Product Reliability: A "no-solder zone" is established at the base of the enameled wire to effectively prevent potential damage to the wire insulation from soldering heat and flux, reducing the risk of wire breakage and insulation failure. Controlling assembly distances and plastic sheath length ensures the stability of the mechanical structure and the reliability of electrical connections.

[0018] 3. Strengthen process quality control: Quality control measures such as regular temperature calibration, timed inspection records, and full inspection of key dimensions have been introduced to monitor process parameters and trace product quality, which is conducive to timely detection and correction of deviations and continuous improvement of yield rate.

[0019] 4. Improve production efficiency and operability: By adopting specialized tooling (such as tin-dipping fixtures and spacing jigs) and equipping standard equipment (thermal soldering stations and timing devices), the over-reliance on operator skills is reduced, the difficulty of operation is simplified, and the efficiency of operation and the replicability of production are improved.

[0020] 5. Complete solution: This invention not only provides a standardized method, but also designs a matching production line, forming a complete solution integrating method, equipment, tooling, and quality control, which is convenient for rapid implementation and application in actual production. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the assembly process of the present invention; Figure 2 This is a schematic diagram of the Rogowski coil structure of the present invention; In the diagram: 1. Enamelled wire core; 2. Silicone tubing; 3. Conductor; 4. Circuit board; 5. First threaded sleeve; 6. First lead; 7. Second lead; 8. Second threaded sleeve; 9. Copper hoop. Detailed Implementation

[0022] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings and examples. The following examples are only used to more clearly illustrate the technical solutions of the present invention and should not be construed as limiting the scope of protection of the present invention.

[0023] A method for assembling a Rogowski coil, the Rogowski coil comprising a silicone tube 2 of predetermined length, an enameled wire core 1 disposed inside the silicone tube 2, both ends of the silicone tube 2 being trimmed to be flush with the corresponding end faces of the enameled wire core 1, a circuit board 4 disposed outside one end of the enameled wire core 1, a first lead 6 extending from the corresponding end face of the enameled wire core 1, the first lead 6 being electrically connected to the circuit board 4, a lead wire 3 extending from the circuit board 4 and located outside the silicone tube 2, a copper clamp 9 being provided near the end face of the silicone tube 2 for tightening, and then the circuit board 4, the lead wire 3 and the end of the silicone tube 2 being sealed by a first threaded sleeve 5, so that the circuit board 4, the lead wire 3 and the enameled wire core 1 form a stable connection; The other end of the enameled wire core 1 also has a second lead 7. The second lead 7 has a protective layer on its outer peripheral surface at a certain distance away from the end face of the enameled wire core 1. The silicone tube 2 is tightened with a copper hoop 9 near the end face, and then the lead is encapsulated by the second threaded sleeve 8. The second threaded sleeve 8 can be connected with the first threaded sleeve 5 to make the Rogowski coil in a ring state.

[0024] This embodiment describes in detail the implementation process of the Rogowski coil assembly method.

[0025] First, the overall assembly process is divided into two main steps: wire bonding tread trimming (P1) and lead wire soldering copper tube pressing (P2), which are performed sequentially.

[0026] Process P1: Wire bonding tread trimming process, specifically including: (1) Silicone tube trimming: Trim the protective silicone tube to the specified length according to the drawing requirements, so that one end of the silicone tube is trimmed to be flush with the corresponding end face of the inner core of the enameled wire.

[0027] (2) Circuit board soldering: Before soldering the enameled wire to the circuit board, a 1.5 mm thick stainless steel sheet is used as a special spacing fixture. The sheet is inserted between the circuit board and the inner core of the enameled wire of the Rogowski coil to ensure that the two are parallel and close to the sheet. Then, the lead wires of the corresponding end face of the inner core of the enameled wire are inserted into the circuit board, and then temporary fixation or direct soldering is performed in this state, so as to ensure that the assembly distance between the two is precisely controlled within 1.5 ± 0.5 mm.

[0028] Use an automatic soldering machine to solder the circuit board to the enameled wire leads.

[0029] (3) Lead wire trimming: With the circuit board facing down, align the first lead wire with the center of the round hole (placed vertically), step on the pedal to trim, and trim the lead wire length ≤ 1.5mm.

[0030] Process P2: The process of soldering copper tubes onto the second lead, specifically including: (1) Silicone tube trimming: Trim the protective silicone tube to the specified length according to the drawing requirements, so that the other end of the silicone tube is trimmed to be flush with the corresponding end face of the inner core of the enameled wire.

[0031] (1) Tinning the leads of the enameled wire: Preparation: Fix the enameled wire to be tinned (after completing step P1) onto a dedicated tinning fixture. This fixture is equipped with a height limit stop to ensure that when the enameled wire lead is immersed in the solder, a length of 1.2 cm (example value, within the range of 1.0-1.5 cm) of its root is blocked by the stop and cannot come into contact with the solder, thus naturally forming a "tin-free zone".

[0032] Soldering procedure: Use a constant temperature soldering station set to 380℃ (e.g., a white light soldering station). Turn on the timer (set to 2.0 seconds) and vertically immerse the part of the enameled wire that needs to be soldered (excluding the solder-free area) into the solder bath. After 2.0 seconds, immediately remove the wire and check the soldering effect. It should be bright and full, without solder beads or spikes.

[0033] (2) Pre-installation of copper tubes for circuit board welding: First, put the copper hoops for connection into the designated position.

[0034] Specifically, the silicone tube has copper clamps at both ends near the end face for tightening. Then, the circuit board, wires, and end plates of the silicone tube are sealed by the first threaded sleeve, so that the circuit board, wires, and the inner core of the enameled wire form a stable connection. The other end lead is then encapsulated by a second threaded sleeve, which can be connected to the first threaded sleeve to make the Rogowski coil form a ring.

[0035] Quality control is performed during the assembly process: Equipment inspection: Before and during each work shift, use a calibrated temperature tester to calibrate and record the actual temperature of the constant temperature welding station to ensure that it is stable within the range of 380±5℃.

[0036] Regular inspections: Quality inspectors conduct spot checks on the soldering temperature setting and actual tinning time of the P2 process every 2 hours and record them on the inspection sheet.

[0037] 100% inspection: For each finished product, use calipers or special go / no-go gauges to inspect the assembly distance between the circuit board and the core, and the length of the plastic wrapping at the lead crimping. Defective products are immediately isolated and reworked.

[0038] This embodiment provides an assembly production line for implementing the method described in Embodiment 1.

[0039] The production line is laid out according to the technological process, and includes, in sequence: The first processing unit is used to perform the circuit board trimming process (P1). The second processing unit is used to perform the lead-on tin-copper tube pressing process (P2). First processing unit (corresponding to process area P1): equipped with a silicone tube cutting station; Automatic soldering machine circuit board soldering station: equipped with constant temperature soldering iron, desoldering pump, etc. A special spacing fixture (1.5mm thick guide plate) is placed nearby. Lead wire cutting; this area mainly involves soldering and trimming of the circuit board.

[0040] The second processing unit (corresponding to process area P2): This is the core processing area, with the following equipment and workstations connected in series: 1. Thermostatic soldering station: Model QUICK 200M, temperature set and locked at 380℃, with digital display.

[0041] 2. Timing device: It is an independent digital display timer, placed together with the soldering station. The operator sets it to start after 2.0 seconds, and a buzzer sounds to indicate that it will start.

[0042] 3. Limiting fixture (soldering clamp): A custom-made clamp with adjustable or fixed height stops to ensure the formation of a 1.0-1.5 cm solder-free zone during soldering.

[0043] 4. Pre-installation of copper tubes for circuit board welding: First, put the copper clamps for connection into the designated positions.

[0044] Inspection area: Located at the end of the production line, it is equipped with inspection tools such as image measuring instruments or dial gauges for carrying out 100% inspection.

[0045] This production line solidifies the key control points in the method patent into the production system by standardizing equipment parameters and tooling operational actions, ensuring that the standardized method can be executed efficiently and accurately.

[0046] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for assembling a Rogowski coil, characterized in that, The assembly process of Rogowski coils is divided into at least two sequential steps: wire bonding pedal trimming (P1) and lead soldering copper tube pressing (P2). The process P1 includes silicone tube trimming, circuit board soldering, and lead wire trimming. The process P2 includes silicone tube trimming, tinning of enameled wire, and crimping of copper tubes; In the tinning step of the enameled wire in process P2, a 1.0-1.5 cm length region at the root of the enameled wire is designated as a tin-free zone, and tinning is applied to the non-tin-free zone. In the tinning step of the enameled wire in process P2, a constant temperature soldering station is used to control the soldering temperature at 380±5℃ and the tinning time at 2.0 seconds.

2. The Rogowski coil assembly method according to claim 1, characterized in that, Before the circuit board soldering step in process P1, the following step is also included: Using a dedicated spacing fixture, the assembly distance between the circuit board and the inner core of the Rogowski coil is controlled to be 1.5 ± 0.5 mm.

3. The Rogowski coil assembly method according to claim 1, characterized in that, In the lead wire trimming step of process P1, the lead wire length is controlled to be no more than 1.5 mm.

4. The Rogowski coil assembly method according to claim 1, characterized in that, The method further includes the following steps: The temperature of the constant temperature welding station shall be calibrated regularly, with a calibration frequency of no less than twice per work shift.

5. A Rogowski coil assembly method according to claim 1, characterized in that, The tin-free zone at the root of the enameled wire is set by using a tin-dipping fixture with a height limiting block.

6. A Rogowski coil assembly method according to claim 1, characterized in that, The special spacing fixture is a sheet gauge plate with a thickness of 1.5 mm.

7. A Rogowski coil assembly method according to claim 1, characterized in that, The method further includes a quality control step, which includes: The welding temperature and tinning time are regularly inspected and recorded. The assembly distance between the circuit board and the core, and the length of the plastic wrapping at the lead crimping point are all inspected.

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