Large-capacity amorphous alloy three-dimensional winding core single-frame forming automatic equipment

Abstract

This invention provides an automated equipment for forming large-capacity amorphous alloy three-dimensional coiled iron core frames, including a forming station, a curing station, an automatic gluing station, and posture adjustment components. The forming station is used to press and form the iron core frame; the curing station is used to anneal and cure the formed iron core frame; the automatic gluing station is used to apply glue to the cured iron core frame; multiple posture adjustment components are respectively set at the forming station, curing station, and automatic gluing station for clamping and / or flipping the iron core frame. This connects the originally discrete processes into a continuous production line, realizing the automatic flow of the iron core frame between the stations. This feature completely eliminates the reliance on manual labor or cranes for material transfer in traditional processes, significantly improving production efficiency and fundamentally avoiding physical damage to the brittle amorphous alloy after annealing caused by repeated handling.

Description

Technical Field

[0001] This invention belongs to the field of transformer core manufacturing technology, specifically relating to an automated single-frame forming equipment for large-capacity amorphous alloy three-dimensional wound cores. Background Technology

[0002] Amorphous alloy three-dimensional wound cores are widely used in the field of high-efficiency energy-saving transformers due to their advantages such as perfectly symmetrical three-phase magnetic circuits, low no-load loss, and significant energy-saving effect. These cores are typically composed of three identical rectangular frames assembled together. In existing technologies, the forming process of a single frame mainly includes: placing the wound non-standard rectangular frame on a forming mold for shaping, followed by annealing, and finally coating and curing with epoxy resin to fix the shape.

[0003] However, existing forming processes and equipment exhibit the following problems when handling large-capacity (i.e., large-size and heavy) amorphous alloy core frames: The processes are discrete and have a low degree of automation: forming, annealing, and coating processes are usually carried out in steps on different equipment, requiring multiple lifting and transfers. Amorphous alloy strips are extremely brittle after annealing, and repeated handling can easily lead to core edge breakage and performance deterioration.

[0004] Molding precision is difficult to guarantee: Traditional molding molds are mostly fixed structures. For large-sized single frames, it is difficult to provide uniform and controllable clamping force during the molding process, resulting in irregular core cross-sectional shape and affecting the tightness of subsequent assembly of three single frames.

[0005] Large-capacity iron cores are difficult to handle: As transformer capacity increases, the weight and volume of a single frame increase significantly. Relying on manual labor or simple machinery to turn them over and apply glue is not only inefficient, but also poses a significant safety risk. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide an automated equipment for forming large-capacity amorphous alloy three-dimensional coiled iron core single frame. This equipment integrates forming, curing and transfer functions, and can realize high-precision, high-efficiency and low-loss automated production of large-size single frames.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows: This invention provides an automated equipment for forming a large-capacity amorphous alloy three-dimensional wound iron core single frame, comprising a forming station, a curing station, an automatic gluing station, and a posture adjustment component, wherein: The forming station is used to press and form the iron core frame; The curing station is used to anneal and cure the formed iron core frame. The automatic glue application station is used to apply glue to the cured iron core frame. Multiple posture adjustment components are provided, respectively set in the forming station, curing station and automatic glue application station, for clamping and / or flipping the iron core frame.

[0008] Preferably, the forming station includes a gantry frame, and a servo clamping drive device is installed at the upper end, lower end, left side and right side of the gantry frame. Each servo clamping drive device is connected to a forming module. The working surface of each forming module matches the theoretical shape of the iron core frame.

[0009] Preferably, the working surfaces of the left and right forming modules are adjustable-angle inclined plane structures; the working surfaces of the upper and lower forming modules are segmented floating structures.

[0010] Preferably, the automatic glue application station includes a movable glue application head and a glue supply system, wherein the outlet of the glue supply system is connected to the inlet of the movable glue application head.

[0011] Preferably, the attitude adjustment assembly includes a clamping arm, a C-shaped flipping arm, a clamping driver, and a flipping driver, wherein: There are two clamping drivers, which are respectively installed at both ends of the C-shaped flip arm, and each clamping driver drives and connects to a clamping arm; The flip drive is mounted on the base and is connected to the C-type flip arm drive.

[0012] Preferably, the molding station, curing station and automatic glue application station are sequentially connected by an automatic transmission system for carrying and transferring the iron core frame.

[0013] Preferably, both the molding station and the automatic gluing station are equipped with multiple accompanying clamps, which are inserted into the inner window of the iron core frame for pre-positioning.

[0014] Preferably, the accompanying fixture includes a base, on which an inner support positioning core mold is provided. The inner support positioning core mold is used to insert into the inner window of the iron core frame and pre-position it.

[0015] Preferably, the control unit is also connected to a pressure sensor, a displacement sensor, and a laser contour scanner installed at the molding station.

[0016] Preferably, both the pressure sensor and the displacement sensor are mounted on the servo clamping drive device to collect the clamping force and displacement of the molding module in real time. The laser profile scanner is installed on the gantry frame and is used to collect the outline data of the iron core frame in real time.

[0017] Compared with the prior art, the beneficial effects of the present invention are: This invention provides an automated equipment for forming large-capacity amorphous alloy three-dimensional coiled iron core single frames. Addressing the problems of discrete processes in existing technologies, such as damage to the iron core due to repeated handling, difficulty in ensuring forming accuracy, and challenges in processing large-capacity iron cores, this invention integrates forming, curing, and automatic gluing stations, along with multiple posture adjustment components, to achieve a fully integrated operation of the iron core single frame from compression forming to annealing curing and gluing. This eliminates the need for repeated lifting and transfer between different devices, effectively avoiding edge breakage and performance degradation caused by the high brittleness of amorphous alloys after annealing. Simultaneously, the multiple posture adjustment components ensure that large-size, heavy iron core single frames can be stably clamped and rotated as needed between stations. This not only solves the safety risks and low efficiency problems associated with manual or simple mechanical handling of large-capacity iron cores but also provides a reliable positioning basis for subsequent high-precision processing at each station, significantly improving overall production efficiency and yield.

[0018] Furthermore, by setting up a gantry frame and installing independent servo clamping drive devices and matching forming modules in the top, bottom, left, and right directions, multi-directional synchronous or sequential clamping of the core frame is achieved. Compared to traditional single-direction or simple template forming methods, this structure can apply uniform and controllable clamping force to the core frame from four directions, ensuring that the large-size core frame is subjected to balanced force during the forming process, significantly improving its shape regularity and dimensional consistency, and laying the foundation for the high-precision assembly of the subsequent three frames.

[0019] Furthermore, the left and right forming modules employ an adjustable-angle inclined surface structure, while the upper and lower forming modules utilize a segmented floating structure. These two technical features work together to allow the forming modules to adaptively adjust their contact state according to the actual geometry and deformation of the core frame. The inclined surface structure precisely matches the tilt angle of the core's sides, while the segmented floating structure compensates for local unevenness on the upper and lower surfaces of the core. This effectively avoids the problems of local overpressure damage or insufficient forming caused by traditional rigid molds, further improving the forming quality.

[0020] Furthermore, the attitude adjustment component, through the organic combination of clamping driver, clamping arm, C-shaped tilting arm, and tilting driver, constructs an integrated unit capable of simultaneously performing clamping and tilting functions. This component can stably clamp and change the attitude of the iron core frame at each workstation without adding additional handling equipment. This solves the problem of the difficulty and danger of manually tilting large-capacity iron cores, while ensuring that the iron core is always in the optimal processing posture during automated production, thus improving the flexibility and automation level of the production line.

[0021] Furthermore, by setting up an automated transfer system between the molding, curing, and gluing stations, the originally discrete processes are connected into a continuous production line, realizing the automatic flow of the iron core frame between each station. This feature completely eliminates the links in the traditional process that rely on manual labor or cranes for material transfer, which not only greatly improves production efficiency, but also fundamentally avoids the physical damage caused to the brittle amorphous alloy after annealing by repeated handling. Detailed Implementation

[0022] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0023] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.

[0024] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0025] As used in this application specification and the appended claims, the term "if" may be interpreted, depending on the context, as "when," "once," "in response to determination," or "in response to detection." Similarly, the phrase "if determined" or "if detected [the described condition or event]" may be interpreted, depending on the context, as meaning "once determined," "in response to determination," "once detected [the described condition or event]," or "in response to detection [the described condition or event]."

[0026] Furthermore, in the description of this application and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0027] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0028] Example 1 This embodiment provides an automated equipment for forming a large-capacity amorphous alloy three-dimensional wound core single frame, including a forming station, a curing station, an automatic gluing station, and a posture adjustment component, wherein: The forming station is used to press and form the iron core frame; The curing station is used to anneal and cure the formed iron core frame. The automatic glue application station is used to apply glue to the cured iron core frame. Multiple posture adjustment components are provided, respectively set in the forming station, curing station and automatic glue application station, for clamping and / or flipping the iron core frame.

[0029] Example 2 Based on Example 1, this example provides an automated equipment for forming a large-capacity amorphous alloy three-dimensional coiled iron core single frame. The forming and curing integrated station includes a gantry frame. A servo clamping drive device is installed at the upper end, lower end, left side and right side of the gantry frame. Each servo clamping drive device is connected to a forming module. The working surface of each forming module matches the theoretical shape of the iron core single frame.

[0030] This embodiment achieves multi-directional synchronous or sequential clamping of the core frame by setting up a gantry frame and installing independent servo clamping drive devices and matching forming modules in the four directions of top, bottom, left, and right. Compared with the traditional single-direction or simple template forming method, this structure can apply uniform and controllable clamping force to the core frame from four directions, ensuring that the large-size core frame is subjected to balanced force during the forming process, significantly improving its shape regularity and dimensional consistency, and laying the foundation for the high-precision assembly of the three frames in the future.

[0031] Example 3 Based on Example 1, this example provides an automatic equipment for forming a single frame of a large-capacity amorphous alloy three-dimensional coiled iron core. The working surfaces of the left and right forming modules adopt an adjustable angle inclined structure, and the working surfaces of the upper and lower forming modules are segmented floating structures. This allows for adaptive adjustment of the contact state according to the actual deformation of the iron core frame, avoiding the local overpressure or false pressure problems caused by traditional rigid templates.

[0032] In this embodiment, the left and right molding modules include a substrate, the back side of which is connected to a servo pressing drive device, and the front side of which is movably connected to a working surface.

[0033] The upper and lower forming modules include a substrate. The back side of the substrate is connected to a servo pressing drive device. The front side of the substrate is elastically connected to multiple working sub-surfaces, which are spliced ​​together to form a segmented floating structure working surface.

[0034] Example 4 Based on Example 1, this example provides an automatic equipment for forming a large-capacity amorphous alloy three-dimensional coiled iron core single frame. Both the forming station and the automatic glue application station are equipped with multiple accompanying clamps, which are inserted into the inner window of the iron core single frame for pre-positioning.

[0035] In this embodiment, the accompanying fixture includes a base and an inner support positioning core mold disposed on the base. The inner support positioning core mold is used to insert into the inner window of the iron core frame and pre-position it. The base is detachably installed on the rotating work platform.

[0036] Example 5 Based on Example 1, this example provides an automated equipment for forming a single frame of a large-capacity amorphous alloy three-dimensional coiled iron core. The attitude adjustment component includes a clamping arm, a C-shaped flipping arm, a clamping driver, and a flipping driver, wherein: There are two clamping drivers, which are respectively installed at both ends of the C-shaped flip arm, and each clamping driver drives and connects to a clamping arm; The flip drive is mounted on the base and is connected to the C-type flip arm drive.

[0037] The component involved in this embodiment can stably clamp and change the posture of the iron core frame at each workstation without adding additional handling equipment. This solves the problem of the difficulty and danger of manually flipping large-capacity iron cores, and ensures that the iron core is always in the optimal processing posture during the automated production process, thereby improving the flexibility and automation level of the production line.

[0038] Example 6 Based on Example 1, this example provides an automated equipment for forming a large-capacity amorphous alloy three-dimensional coiled iron core single frame. The curing station is an annealing device, including an infrared radiation heating plate or a hot air circulation system, whose heating area covers the iron core single frame placed in the forming mechanism.

[0039] Example 7 Based on Example 1, this example provides an automated equipment for forming a large-capacity amorphous alloy three-dimensional coiled iron core single frame. The automated glue application device includes a movable glue application head and a glue supply system, wherein: The outlet of the glue supply system is connected to the inlet of the movable glue applicator.

[0040] Example 8 Based on Example 1, this example provides an automated equipment for forming a single frame of a large-capacity amorphous alloy three-dimensional coiled iron core. The automated equipment further includes a control unit connected to a pressure sensor, a displacement sensor, and a laser contour scanner. Both the pressure sensor and the displacement sensor are installed on the servo clamping drive device to collect the clamping force and moving displacement of the molding module in real time. The laser contour scanner is installed on the gantry frame and is used to collect the outline data of the iron core frame in real time. The control unit is embedded with a theoretical three-dimensional model of the iron core frame. Based on the feedback data from the pressure sensor, displacement sensor and laser contour scanner, it dynamically adjusts the servo clamping drive device to achieve closed-loop control of the forming process. This ensures that the formed iron core frame is highly consistent with the theoretical design and significantly improves the accuracy of the three-frame assembly.

[0041] Example 9 This embodiment provides a method for using an automated equipment for forming a single frame of a large-capacity amorphous alloy three-dimensional wound iron core, including the following steps: The wound iron core frame is clamped and placed on the accompanying fixture at the forming station using the attitude adjustment component, and the accompanying fixture is used to pre-position it. The servo clamping drive devices in the four directions of up, down, left, and right operate simultaneously, driving their respective forming modules to apply clamping force to the iron core frame.

[0042] The working surfaces of the left and right forming modules are adjustable-angle inclined structures to adapt to the slope of the iron core side; The working surfaces of the upper and lower forming modules are segmented floating structures, which can adaptively adjust the contact state according to the actual deformation of the iron core to avoid local overpressure or false pressure.

[0043] Based on real-time feedback from pressure sensors, displacement sensors, and laser profile scanners, the clamping force and position of each servo drive device are dynamically adjusted to ensure that the core shape closely matches the theoretical three-dimensional model. After molding is completed, the core frame is transferred to the curing station using the posture adjustment component.

[0044] The curing station uses an infrared radiation heating plate or a hot air circulation system to anneal the iron core frame, eliminate internal stress, and cure its shape. After curing, the core frame is moved to the automatic glue application station using the attitude adjustment component and placed on the accompanying fixture. The movable glue application head is adjusted to apply glue to one surface of the core frame. Then, the core frame is flipped over using the attitude adjustment component to complete the glue application on the other surface.

[0045] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. An automated equipment for forming a single frame of a large-capacity amorphous alloy three-dimensional wound iron core, characterized in that, This includes a molding station, a curing station, an automatic gluing station, and a posture adjustment component, among which: The forming station is used to press and form the iron core frame; The curing station is used to anneal and cure the formed iron core frame. The automatic glue application station is used to apply glue to the cured iron core frame. Multiple posture adjustment components are provided, respectively set in the forming station, curing station and automatic glue application station, for clamping and / or flipping the iron core frame.

2. The automated equipment for forming a single frame of a large-capacity amorphous alloy three-dimensional coiled iron core according to claim 1, characterized in that, The forming station includes a gantry frame, and a servo clamping drive device is installed at the upper end, lower end, left side and right side of the gantry frame. Each servo clamping drive device is connected to a forming module. The working surface of each forming module matches the theoretical shape of the iron core frame.

3. The automated equipment for single-frame forming of large-capacity amorphous alloy three-dimensional wound iron core according to claim 2, characterized in that, The working surfaces of the left and right forming modules are adjustable-angle inclined plane structures; the working surfaces of the upper and lower forming modules are segmented floating structures.

4. The automated equipment for single-frame forming of large-capacity amorphous alloy three-dimensional wound iron core according to claim 1, characterized in that, The automatic glue application station includes a movable glue application head and a glue supply system, wherein the outlet of the glue supply system is connected to the inlet of the movable glue application head.

5. The automated equipment for forming a single frame of a large-capacity amorphous alloy three-dimensional wound iron core according to claim 1, characterized in that, The attitude adjustment assembly includes a clamping arm, a C-shaped flipping arm, a clamping driver, and a flipping driver, wherein: There are two clamping drivers, which are respectively installed at both ends of the C-shaped flip arm, and each clamping driver drives and connects to a clamping arm; The flip drive is mounted on the base and is connected to the C-type flip arm drive.

6. The automated equipment for single-frame forming of large-capacity amorphous alloy three-dimensional wound iron core according to claim 1, characterized in that, The molding station, curing station, and automatic glue application station are sequentially connected by an automatic transmission system for carrying and transferring the iron core frame.

7. The automated equipment for single-frame forming of large-capacity amorphous alloy three-dimensional coiled iron core according to claim 1, characterized in that, Both the molding station and the automatic gluing station are equipped with multiple accompanying clamps, which are inserted into the inner window of the iron core frame for pre-positioning.

8. The automated equipment for single-frame forming of large-capacity amorphous alloy three-dimensional wound iron core according to claim 7, characterized in that, The accompanying fixture includes a base, on which an inner support positioning core mold is provided. The inner support positioning core mold is used to insert into the inner window of the iron core frame and pre-position it.

9. The automated equipment for single-frame forming of large-capacity amorphous alloy three-dimensional wound iron core according to claim 1, characterized in that, The control unit is also connected to a pressure sensor, a displacement sensor, and a laser contour scanner installed at the molding station.

10. The automated equipment for forming a single frame of a large-capacity amorphous alloy three-dimensional wound iron core according to claim 9, characterized in that, Both the pressure sensor and the displacement sensor are installed on the servo clamping drive device to collect the clamping force and moving displacement of the molding module in real time. The laser profile scanner is installed on the gantry frame and is used to collect the outline data of the iron core frame in real time.