A versatile transformer assembly device

Abstract

This invention relates to the field of transformer manufacturing technology, and in particular to a versatile transformer assembly device, comprising an assembly platform, a slider, a positioning and clamping mechanism, a moving drive mechanism, and a core assembly robot. The assembly platform has a sliding groove, within which the slider slides. The positioning and clamping mechanism is mounted on the assembly platform, with its two clamping ends located within the sliding groove. The slider can move relative to the positioning and clamping mechanism. The slider has a support block with a clearance slot in its center, allowing the two clamping ends of the positioning and clamping mechanism to be accommodated within the clearance slot. The top surface of the support block has a positioning reference surface. This invention enables the assembly of the coil winding and the core into a transformer. During assembly, the coil winding can be positioned with its pins facing upwards or downwards, and the positioning accuracy is high. It is suitable for assembling EP-type, EE-type, and EFD-type transformers, demonstrating good versatility.

Description

Technical Field

[0001] This invention relates to the field of transformer manufacturing technology, and in particular to a versatile transformer assembly device. Background Technology

[0002] In the transformer manufacturing process, the assembly of the coil winding and the magnetic core is one of the core processes. The assembly accuracy directly determines the electromagnetic conversion efficiency, insulation performance and overall service life of the transformer. Especially in the mass production of commonly used small transformers such as EP type, EE type and EFD type, the versatility and positioning accuracy of the assembly equipment are key factors affecting production efficiency and product qualification rate.

[0003] Currently, most transformer assembly equipment on the market is designed for specific transformer models or pin orientations, resulting in poor versatility. As electronic equipment becomes increasingly miniaturized and diversified, production processes often require switching between different transformer structures such as EP, EE, and EFD. These specialized assembly devices necessitate frequent adjustments to tooling structures and replacement of positioning components, increasing equipment debugging time, reducing production efficiency, raising tooling maintenance costs, and increasing operator workload. This makes them ill-suited for the demands of multi-variety, small-batch production. Furthermore, EP-type transformers have a unique arc-shaped insulation structure in their coil windings, while EFD-type transformers feature a thinner profile; existing equipment struggles to simultaneously accommodate the assembly needs of these different transformer structures.

[0004] Meanwhile, existing assembly devices often use inappropriate positioning references when positioning and supporting the coil windings, resulting in insufficient positioning accuracy. Some devices use the coil winding pins as the positioning reference, but these pins are prone to deformation during processing and transportation, directly affecting positioning accuracy. This leads to misalignment between the magnetic core and the coil winding during assembly, causing problems such as uneven magnetic circuits and increased leakage inductance. In severe cases, it can even cause contact breakdown between the winding and the magnetic core, affecting the quality of the transformer product. Furthermore, some devices have poorly designed support structures. When the coil winding pins are placed upwards, they cannot provide stable support and accurate positioning for the pins or insulators, especially failing to adapt to the arc structure of the EP-type transformer insulator, easily leading to support interference and positioning misalignment. When the pins are placed downwards, they cannot provide effective support for the pins, similarly reducing positioning accuracy.

[0005] Therefore, the defects are very obvious, and a solution is urgently needed. Summary of the Invention

[0006] In order to solve the above-mentioned technical problems, the purpose of this invention is to provide a transformer assembly device with good versatility.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: A versatile transformer assembly device includes an assembly platform, a slider, a positioning and clamping mechanism, a moving drive mechanism for driving the slider to reciprocate, and a core assembly robot disposed on the side of the assembly platform. The assembly platform has a slide groove, in which the slider is slidably disposed. The positioning and clamping mechanism is mounted on the assembly platform, with its two clamping ends located within the slide groove. The two clamping ends of the positioning and clamping mechanism can move closer to or further away from each other along the extension direction of the slide groove. The slider can move relative to the positioning and clamping mechanism. The slider has a support block with a clearance slot in its center, in which the two clamping ends of the positioning and clamping mechanism can be accommodated. The top surface of the support block has a positioning reference surface. The support block supports the coil winding, the positioning reference surface provides a positioning reference for the coil winding, the positioning and clamping mechanism clamps the coil winding supported by the support block, and the core assembly robot assembles the magnetic core onto the coil winding clamped by the positioning and clamping mechanism.

[0008] Furthermore, the positioning and clamping mechanism includes a clamping driver installed on the bottom surface of the assembly platform and two clamping blocks respectively installed on two clamping parts of the clamping driver. The bottom wall of the slide groove is provided with a movable hole, and the clamping blocks extend into the slide groove through the movable hole. The two clamping blocks can move closer or further away from each other in the movable hole, and the two clamping blocks can be accommodated in the clearance groove.

[0009] Furthermore, protective pads are provided on the sides of the two clamping blocks that are close to each other.

[0010] Furthermore, the inner wall of the slide is recessed with a limiting guide groove, and the side of the slider is protruded with a limiting guide block that slides in cooperation with the limiting guide groove.

[0011] Furthermore, there are two support blocks and two positioning clamping mechanisms, with each support block corresponding to one of the two positioning clamping mechanisms.

[0012] Furthermore, the magnetic core assembly robot includes a support platform, an assembly traversing mechanism mounted on the support platform, an assembly lifting mechanism mounted on the traversing part of the assembly traversing mechanism, a lifting seat mounted on the lifting part of the assembly lifting mechanism, and two clamping mechanisms mounted on the lifting seat. The clamping mechanisms are used to clamp the magnetic core, and the two clamping mechanisms are respectively configured to correspond one-to-one with the two positioning and clamping mechanisms.

[0013] Furthermore, there are two magnetic core assembly robots, which are arranged opposite each other, with the assembly platform located between the two magnetic core assembly robots.

[0014] Furthermore, the magnetic core assembly robot also includes a rubber-grinding drive mechanism mounted on the lifting seat, and two clamping mechanisms are respectively mounted on the two drive parts of the rubber-grinding drive mechanism. The rubber-grinding drive mechanism drives the two clamping mechanisms to move closer or further apart from each other.

[0015] Furthermore, the moving part of the moving drive mechanism is provided with a quick-release head, and one end of the slider is provided with a quick-release groove. The quick-release head is detachably mounted in the quick-release groove.

[0016] Furthermore, the clamping mechanism includes a clamping cylinder and two clamping blocks respectively installed on two clamping parts of the clamping cylinder. The clamping cylinder is used to drive the two clamping blocks to move closer or further away from each other. A positioning step is provided on the side of the clamping blocks that are close to each other.

[0017] The beneficial effects of this invention are as follows: In practical applications, initially, the two clamping ends of the positioning and clamping mechanism are located in the clearance slot and are in an open state. The external coil winding robot places the coil winding on the support block. The positioning reference surface on the support block provides a positioning reference for the coil winding to ensure that the coil winding is at a preset height position. Then, the two clamping ends of the positioning and clamping mechanism clamp and position the two sides of the coil winding on the positioning reference surface. Then, the moving drive mechanism drives the slider to translate, so that the support block is separated from the coil winding, and the part of the coil winding where the magnetic core is installed is exposed. Then, the magnetic core assembly robot assembles the magnetic core it holds laterally onto the coil winding after it has been clamped and positioned, so as to realize the assembly of the coil winding and the magnetic core. After the assembly is completed, the external transfer robot removes the assembled coil winding and magnetic core. Finally, the moving drive mechanism drives the slider to translate and reset, so that the support block on the slider can support the next coil winding. Because the support block is equipped with clearance slots, when the pins on the coil winding face upwards, the support block can support the insulator on the coil winding. The positioning reference surface on the support block provides a positioning reference for the insulator on the coil winding. Due to the high processing / production precision of the coil winding insulator, it is not affected by factors such as pin deformation on the coil winding, resulting in high positional accuracy of the coil winding on the support block. This is particularly suitable for assembling EP type transformers. The insulator of the coil winding of the EP type transformer has an arc structure. When the pins of the coil winding face upwards, the clearance slots can provide clearance space for the arc structure on the insulator of the coil winding of the EP type transformer. In addition, when the pins of the coil winding face downwards, the support block supports the pins of the coil winding, and the positioning reference surface on the support block provides a positioning reference for the pins of the coil winding, ensuring the positional accuracy of the coil winding on the support block. This can meet the assembly requirements of EP type transformers, EE type transformers, and EFD type transformers. This invention enables the assembly of coil windings and magnetic cores to form a transformer. During the assembly process, the coil winding pins can be facing up or down, and the positioning accuracy is high. It meets the requirements for assembling and producing EP type transformers, EE type transformers and EFD type transformers. It has good versatility and strong practicality. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0019] Figure 2 This is a three-dimensional structural diagram of the robot arm assembled with the hidden magnetic core of the present invention.

[0020] Figure 3 This is an exploded structural diagram of the robot arm assembled with the hidden magnetic core of the present invention.

[0021] Figure 4 This is a three-dimensional structural diagram of the moving drive mechanism and slider of the present invention.

[0022] Figure 5 This is a three-dimensional structural diagram of the magnetic core assembly robot of the present invention.

[0023] Explanation of reference numerals in the attached figures: 1. Assembly platform; 2. Slider; 3. Positioning and clamping mechanism; 4. Moving drive mechanism; 5. Magnetic core assembly robot; 6. Slide groove; 7. Support block; 8. Clearance slot; 9. Positioning reference surface; 10. Wire coil winding; 11. Magnetic core; 12. Clamping driver; 13. Clamping block; 14. Movable hole; 15. Protective pad; 16. Limiting guide groove; 17. Limiting guide block; 18. Support platform; 19. Assembly transverse movement mechanism; 20. Assembly lifting mechanism; 21. Lifting seat; 22. Clamping mechanism; 23. Grinding drive mechanism; 24. Quick-release head; 25. Quick-release slot; 26. Clamping cylinder; 27. Clamping block; 28. Positioning step. Detailed Implementation

[0024] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to embodiments and accompanying drawings. The content mentioned in the embodiments is not intended to limit the present invention.

[0025] like Figures 1 to 5 As shown, the present invention provides a versatile transformer assembly device, comprising an assembly platform 1, a slider 2, a positioning and clamping mechanism 3, a moving drive mechanism 4 for driving the slider 2 to reciprocate, and a magnetic core assembly robot 5 disposed on the side of the assembly platform 1. The assembly platform 1 is provided with a slide groove 6, in which the slider 2 is slidably disposed. The positioning and clamping mechanism 3 is mounted on the assembly platform 1, with its two clamping ends located within the slide groove 6. The two clamping ends of the positioning and clamping mechanism 3 can move closer to or further away from each other along the extending direction of the slide groove 6. The slider 2 can... The positioning clamping mechanism 3 can move relative to the positioning clamping mechanism 3. The slider 2 is provided with a support block 7. The support block 7 has a clearance groove 8 in the middle. The two clamping ends of the positioning clamping mechanism 3 can be accommodated in the clearance groove 8. The top surface of the support block 7 is provided with a positioning reference surface 9. The support block 7 is used to support the coil winding 10. The positioning reference surface 9 provides a positioning reference for the coil winding 10. The positioning clamping mechanism 3 is used to clamp the coil winding 10 supported by the support block 7. The magnetic core assembly robot 5 is used to assemble the magnetic core 11 onto the coil winding 10 clamped by the positioning clamping mechanism 3.

[0026] In practical applications, initially, the two clamping ends of the positioning clamping mechanism 3 are located within the clearance slot 8 and are in an open state. The external coil winding robot places the coil winding 10 on the support block 7. The positioning reference surface 9 on the support block 7 provides a positioning reference for the coil winding 10 to ensure that the coil winding 10 is at a preset height position. Then, the two clamping ends of the positioning clamping mechanism 3 clamp and position the two sides of the coil winding 10 on the positioning reference surface 9. Then, the moving drive mechanism 4 drives the slider 2 to translate, so that the support block 10 is positioned at a preset height. The support block 7 separates from the coil winding 10, exposing the part of the coil winding 10 where the magnetic core 11 is installed. Then, the magnetic core assembly robot 5 assembles the magnetic core 11 it holds laterally onto the coil winding 10 after it has been clamped and positioned, thus assembling the coil winding 10 and the magnetic core 11. After assembly, the external transfer robot removes the assembled coil winding 10 and magnetic core 11. Finally, the moving drive mechanism 4 drives the slider 2 to translate and reset, so that the support block 7 on the slider 2 can support the next coil winding 10. Because the support block 7 is equipped with a clearance slot 8, when the pins on the coil winding 10 are facing upwards, the support block 7 can support the insulator on the coil winding 10. The positioning reference surface 9 on the support block 7 provides a positioning reference for the insulator on the coil winding 10. Due to the high processing / production precision of the insulator of the coil winding 10, it is not affected by factors such as pin deformation on the coil winding 10, resulting in high positional accuracy of the coil winding 10 on the support block 7. This is particularly suitable for assembling EP type transformers. The insulator has an arc structure. When the pins of the coil winding 10 are facing upwards, the clearance slot 8 provides clearance space for the arc structure on the insulator of the coil winding 10 of the EP type transformer. Additionally, when the pins of the coil winding 10 are facing downwards, the support block 7 supports the pins of the coil winding 10. The positioning reference surface 9 on the support block 7 provides a positioning reference for the pins of the coil winding 10, ensuring the positional accuracy of the coil winding 10 on the support block 7. This satisfies the assembly requirements of EP type transformers, EE type transformers, and EFD type transformers. This invention enables the assembly of the coil winding 10 and the magnetic core 11 into a transformer. During assembly, the coil winding 10 can be positioned with either pins facing upwards or downwards, with high positional accuracy. It satisfies the assembly and production requirements of EP type transformers, EE type transformers, and EFD type transformers, demonstrating good versatility and strong practicality.

[0027] In this embodiment, the positioning and clamping mechanism 3 includes a clamping driver 12 mounted on the bottom surface of the assembly platform 1 and two clamping blocks 13 respectively mounted on two clamping parts of the clamping driver 12. The bottom wall of the slide groove 6 has a movable hole 14. The clamping blocks 13 extend into the slide groove 6 through the movable hole 14. The two clamping blocks 13 can move closer to or further away from each other within the movable hole 14. The two clamping blocks 13 can be accommodated in the clearance groove 8. Specifically, the clamping driver 12 can be a finger cylinder.

[0028] In practical applications, the clamping driver 12 drives the two clamping blocks 13 to open, and the external coil winding robot places the coil winding 10 on the support block 7, so that the coil winding 10 is located between the two clamping blocks 13. The positioning reference surface 9 provides a positioning reference for the insulator or pin of the coil winding 10 (preferably providing a positioning reference for the insulator of the coil winding 10). Then, the clamping driver 12 drives the two clamping blocks 13 to move closer to each other until the two clamping blocks 13 clamp the two sides of the coil winding 10 to achieve clamping and positioning of the coil winding 10.

[0029] In this embodiment, a protective pad 15 is provided on the side of the two clamping blocks 13 that are close to each other. When the two clamping blocks 13 clamp the coil winding 10, the protective pad 15 plays a protective role, making it less likely to damage the coil winding 10. When the protective pad 15 is worn, it can be replaced, which reduces maintenance costs and improves maintenance efficiency.

[0030] In this embodiment, a limiting guide groove 16 is recessed on the inner side wall of the slide groove 6, and a limiting guide block 17 is protruding on the side of the slider 2, which slides in cooperation with the limiting guide groove 16. During the process of the moving drive mechanism 4 driving the slider 2 to reciprocate within the slide groove 6, the limiting guide groove 16 and the limiting guide block 17 slide in cooperation to improve the stability of the slider 2's movement.

[0031] In this embodiment, there are two support blocks 7 and two positioning clamping mechanisms 3, with each support block 7 corresponding to one of the two positioning clamping mechanisms 3. This structural design forms a dual-station configuration, enabling the assembly of magnetic cores 11 onto two coil windings 10 at a time, thus improving the efficiency of transformer production.

[0032] In this embodiment, the magnetic core assembly robot 5 includes a support platform 18, an assembly traversing mechanism 19 mounted on the support platform 18, an assembly lifting mechanism 20 mounted on the traversing part of the assembly traversing mechanism 19, a lifting seat 21 mounted on the lifting part of the assembly lifting mechanism 20, and two clamping mechanisms 22 disposed on the lifting seat 21. The clamping mechanisms 22 are used to clamp the magnetic core 11, and the two clamping mechanisms 22 are respectively configured to correspond one-to-one with the two positioning clamping mechanisms 3.

[0033] In practical applications, under the coordinated drive of the assembly lateral movement mechanism 19 and the assembly lifting mechanism 20, the clamping mechanism 22 clamps the magnetic core 11 and assembles the magnetic core 11 onto the coil winding 10 that has been clamped and positioned by the positioning clamping mechanism 3.

[0034] In this embodiment, two magnetic core assembly robots 5 are used, arranged opposite each other, with the assembly platform 1 located between them. In practical applications, the two magnetic core assembly robots 5 assemble the magnetic cores 11 on both sides of the coil winding 10 to form a transformer.

[0035] In this embodiment, the magnetic core assembly robot 5 also includes a glue-grinding drive mechanism 23 mounted on the lifting base 21. Two clamping mechanisms 22 are respectively mounted on the two driving parts of the glue-grinding drive mechanism 23. The glue-grinding drive mechanism 23 drives the two clamping mechanisms 22 to move closer or further away from each other. In practical applications, since the magnetic core 11 is coated with glue before assembly, after the magnetic core 11 is assembled on the side of the coil winding 10, the glue-grinding drive mechanism 23 drives the two clamping mechanisms 22 to move back and forth multiple times, so that the magnetic cores 11 on both sides of the coil winding 10 rub against each other to evenly apply glue, thereby achieving the effect of grinding the inductor.

[0036] In this embodiment, the moving part of the moving drive mechanism 4 is provided with a quick-release head 24, and one end of the slider 2 is provided with a quick-release groove 25. The quick-release head 24 is detachably mounted in the quick-release groove 25. Specifically, the moving drive mechanism 4 can be a cylinder. This structural design facilitates the assembly and disassembly of the slider 2 and the moving drive mechanism 4.

[0037] In this embodiment, the clamping mechanism 22 includes a clamping cylinder 26 mounted on a driving part of the abrasive driving mechanism 23 and two clamping blocks 27 respectively mounted on two clamping parts of the clamping cylinder 26. The clamping cylinder 26 is used to drive the two clamping blocks 27 to move closer or further apart from each other. Each side of the clamping blocks 27 that moves closer to each other is provided with a positioning step 28. Specifically, the clamping cylinder 26 can be a finger cylinder. In practical applications, the clamping mechanism 22 moves to the magnetic core 11, where the magnetic core 11 is located between the two clamping blocks 27. The corners of the magnetic core 11 contact the positioning step 28 to position the magnetic core 11. Then, the clamping cylinder 26 drives the two clamping blocks 27 to move closer to each other until the two clamping blocks 27 clamp the magnetic core 11.

[0038] All technical features in this embodiment can be freely combined according to actual needs.

[0039] The above embodiments are preferred implementations of the present invention. In addition, the present invention can be implemented in other ways. Any obvious substitutions without departing from the concept of the present technical solution are within the protection scope of the present invention.

Claims

1. A versatile transformer assembly device, characterized in that: The assembly platform includes an assembly platform (1), a slider (2), a positioning and clamping mechanism (3), a moving drive mechanism (4) for driving the slider (2) to reciprocate, and a magnetic core assembly robot (5) disposed on the side of the assembly platform (1). The assembly platform (1) is provided with a slide groove (6), and the slider (2) is slidably disposed in the slide groove (6). The positioning and clamping mechanism (3) is mounted on the assembly platform (1), and the two clamping ends of the positioning and clamping mechanism (3) are located in the slide groove (6). The two clamping ends of the positioning and clamping mechanism (3) can move closer to or further away from each other along the extension direction of the slide groove (6). The slider (2) can move relative to the positioning and clamping mechanism (3). The slider (2) is provided with a support block (7), and the support block (7) has a clearance groove (8) in the middle. The two clamping ends of the positioning clamping mechanism (3) can be accommodated in the clearance groove (8). The top surface of the support block (7) is provided with a positioning reference surface (9). The support block (7) is used to support the coil winding (10). The positioning reference surface (9) provides a positioning reference for the coil winding (10). The positioning clamping mechanism (3) is used to clamp the coil winding (10) supported by the support block (7). The magnetic core assembly robot (5) is used to assemble the magnetic core (11) onto the coil winding (10) clamped by the positioning clamping mechanism (3).

2. The versatile transformer assembly device according to claim 1, characterized in that: The positioning and clamping mechanism (3) includes a clamping driver (12) installed on the bottom surface of the assembly platform (1) and two clamping blocks (13) respectively installed on the two clamping parts of the clamping driver (12). The bottom wall of the slide (6) is provided with a movable hole (14). The clamping blocks (13) extend into the slide (6) through the movable hole (14). The two clamping blocks (13) can move closer to or further away from each other in the movable hole (14). The two clamping blocks (13) can be accommodated in the clearance groove (8).

3. The versatile transformer assembly device according to claim 2, characterized in that: A protective pad (15) is provided on the side of the two clamping blocks (13) that are close to each other.

4. The versatile transformer assembly device according to claim 1, characterized in that: The inner wall of the slide groove (6) is recessed with a limiting guide groove (16), and the side of the slider (2) is protruded with a limiting guide block (17) that slides in cooperation with the limiting guide groove (16).

5. The versatile transformer assembly device according to claim 1, characterized in that: The number of support blocks (7) and the number of positioning clamping mechanisms (3) are both two, and the two support blocks (7) are respectively set one-to-one with the two positioning clamping mechanisms (3).

6. The versatile transformer assembly device according to claim 5, characterized in that: The magnetic core assembly robot (5) includes a support platform (18), an assembly traversing mechanism (19) mounted on the support platform (18), an assembly lifting mechanism (20) mounted on the traversing part of the assembly traversing mechanism (19), a lifting seat (21) mounted on the lifting part of the assembly lifting mechanism (20), and two clamping mechanisms (22) set on the lifting seat (21). The clamping mechanism (22) is used to clamp the magnetic core (11), and the two clamping mechanisms (22) are respectively set to correspond one-to-one with the two positioning clamping mechanisms (3).

7. A versatile transformer assembly device according to claim 6, characterized in that: There are two magnetic core assembly robots (5), which are set opposite to each other, and the assembly platform (1) is located between the two magnetic core assembly robots (5).

8. A versatile transformer assembly device according to claim 7, characterized in that: The magnetic core assembly robot (5) also includes a rubber grinding drive mechanism (23) mounted on the lifting seat (21), and two clamping mechanisms (22) are respectively mounted on the two driving parts of the rubber grinding drive mechanism (23). The rubber grinding drive mechanism (23) drives the two clamping mechanisms (22) to move closer or further away from each other.

9. A versatile transformer assembly device according to claim 1, characterized in that: The moving part of the moving drive mechanism (4) is provided with a quick-release head (24), and one end of the slider (2) is provided with a quick-release groove (25). The quick-release head (24) is detachably installed in the quick-release groove (25).

10. A versatile transformer assembly device according to claim 6, characterized in that: The clamping mechanism (22) includes a clamping cylinder (26) and two clamping blocks (27) respectively installed on two clamping parts of the clamping cylinder (26). The clamping cylinder (26) is used to drive the two clamping blocks (27) to move closer or further away from each other. A positioning step (28) is provided on the side of the clamping blocks (27) that moves closer to each other.

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