Transformer assembly method and transformer assembly device

Abstract

To provide transformer assembly method and device that can automate a transformer production process with a simpler configuration.SOLUTION: A transformer assembly method of assembling a transformer including a radially overlapping core made of multiple cylindrical bodies whose ends overlap in the circumferential direction and a pair of adjacent coils includes the following steps: a rising step of passing through the inside of each coil from below a pair of coils by two guide portions, a hooking step in which both ends of a predetermined number of cylindrical bodies are pulled apart and hooked onto the tips of each guide portion, an insertion step in which the cylindrical bodies are lowered together with the two guide sections and inserted into the coil, with both ends hooked onto the tips of each guide section, and a separation step of moving the two guide portions away from the coil to separate them from the cylindrical bodies once the insertion of the cylindrical bodies into the coil is complete.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to a transformer assembling method and an apparatus for assembling a transformer. [Background technology]

[0002] The manufacturing process of a transformer includes, for example, a step of inserting an iron core formed by radially stacking multiple cylindrical bodies having overlapping ends into a pair of adjacent coils whose axial lengths are parallel, with the ends spaced apart and open (see Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 10-135058 Summary of the Invention [Problem to be solved by the invention]

[0004] The process of inserting the iron core into the coil as described above requires the collaboration of multiple workers, which results in low productivity, and because it is a manual process, there is a problem that quality can vary depending on the level of skill of the workers.

[0005] In contrast, although Patent Document 1 discloses automation in the transformer production process, it uses a number of different auxiliary jigs before and after inserting the iron core into the coil, resulting in a complex configuration and complicated operation of the auxiliary jigs.

[0006] The present invention has been made in view of the above circumstances, and has as its object to provide a transformer assembling method and apparatus that can automate the transformer production process with a simpler configuration. [Means for solving the problem]

[0007] The transformer assembly method of the present invention is a transformer assembly method for assembling a transformer having an iron core in which multiple cylindrical bodies whose both ends overlap in the circumferential direction are overlapped radially, and a pair of coils arranged adjacent to each other, and includes the following steps: an ascent step in which two guide parts each pass through the inside of the pair of coils from below the pair of coils and rise; a hooking step in which both ends of a predetermined number of cylindrical bodies are pulled in a direction separating them from each other and hooked onto the tip ends of each guide part; an insertion step in which, with both ends hooked onto the tip ends of each guide part, the unit number of cylindrical bodies are lowered together with the two guide parts and inserted into the coil; and a separation step in which, when the insertion of the unit number of cylindrical bodies into the coil is complete, the two guide parts move in a direction away from the coil and are separated from the unit number of cylindrical bodies.

[0008] The transformer assembly device of the present invention is a transformer assembly device for assembling a transformer in which an iron core made of a plurality of cylindrical bodies whose both ends overlap in the circumferential direction and which are overlapped radially is inserted into a pair of adjacent coils, and is equipped with two guide parts that move up and down passing through the inside of each coil, a holding member that holds a predetermined number of cylindrical bodies above the pair of coils, and a control unit that lowers the holding member and the two guide parts together while both ends of the unit number of cylindrical bodies are hooked onto the tip ends of each guide part, thereby inserting the unit number of cylindrical bodies into the coil, and when the insertion of the unit number of cylindrical bodies into the coil is complete, the control unit moves the two guide parts in a direction away from the coil and separates them from the unit number of cylindrical bodies. [Effects of the Invention]

[0009] According to the present invention, it is possible to provide a transformer assembling method and a transformer assembling apparatus that can automate the transformer production process with a simpler configuration. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view showing an example of a transformer. [Figure 2]FIG. 2 is a schematic side view showing the configuration of a wound core. [Figure 3] 1 is a perspective view of a transformer assembly device according to an embodiment of the present invention. [Figure 4] FIG. 2 is a front view of the transformer assembly device according to the present embodiment. [Figure 5] 1 is a schematic diagram illustrating a main part of a transformer assembly device according to an embodiment of the present invention. [Figure 6] 5 is a flowchart illustrating the process of incorporating a wound core into a coil in the transformer assembly device according to the present embodiment. [Figure 7] 4A to 4C are explanatory diagrams illustrating the process of incorporating a wound core into a coil in the transformer assembly device according to the present embodiment. [Figure 8] 4A to 4C are explanatory diagrams illustrating the process of incorporating a wound core into a coil in the transformer assembly device according to the present embodiment. [Figure 9] 4A to 4C are explanatory diagrams illustrating the process of incorporating a wound core into a coil in the transformer assembly device according to the present embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] The present invention will now be described with reference to the drawings showing embodiments thereof.

[0012] FIG. 1 is a perspective view showing an example of a transformer. In FIG. 1, reference numeral 300 denotes the transformer. The transformer 300 is configured by incorporating one wound iron core 100 (iron core) into two adjacent coils 200. For example, each coil 200 has a hollow rounded rectangular shape in axial cross section, and the wound iron core 100 has an oval shape in axial cross section.

[0013] Fig. 2 is a schematic side view showing the configuration of wound core 100. The view within the ellipse in Fig. 2 is an enlarged view of the portion of wound core 100 enclosed by the dashed ellipse.

[0014] Generally, wound core 100 is obtained by stacking a predetermined number of thin, rectangular core elements, each of which is made by cutting a hoop material such as a silicon steel strip to a predetermined length in the longitudinal direction, and bending the stacked elements to form an ellipse in cross section. In this case, the length of each core element, in other words, the circumferential length of each ellipse core element (hereinafter referred to as a cylindrical element) 111, is longer the outermost cylindrical element 111.

[0015] More specifically, this bending process is performed for each unit number (e.g., 7 to 10) of core blanks, and multiple cylindrical bodies 111 (hereinafter referred to as core blocks 110) obtained from the unit number of core blanks are stacked radially to manufacture the wound core 100. Fig. 2 shows an example in which one core block 110 is made up of eight cylindrical bodies 111, but the present invention is not limited to this.

[0016] That is, in the wound core 100, a plurality of core blocks 110 are overlapped in the radial direction on the same axis, and a plurality of cylindrical bodies 111 are overlapped in the radial direction on the same axis in each core block 110. In the wound core 100, of two radially adjacent core blocks 110, the outer peripheral surface of the inner core block 110 contacts the inner peripheral surface of the outer core block 110, and of two radially adjacent cylindrical bodies 111, the outer peripheral surface of the inner cylindrical body 111 contacts the inner peripheral surface of the outer cylindrical body 111.

[0017] The wound core 100 has an overlapping portion 112 at one end 102 in the longitudinal direction, where both ends 1121, 1122 of each cylindrical body 111 overlap. That is, in each core block 110, the inner end 1121 and the outer end 1122 at the overlapping portion 112 of the cylindrical body 111 overlap in the radial direction of the core block 110, in other words, in the overlapping direction of the cylindrical bodies 111. In each core block 110, the overlapping portions 112 of the cylindrical bodies 111 are arranged so as to be offset by a predetermined interval in one direction in the circumferential direction. Figure 2 shows an example in which the overlapping portions 112 of the cylindrical bodies 111 are offset clockwise.

[0018] That is, in each core block 110, the overlapping portions 112 of the multiple cylindrical bodies 111 do not overlap one another in the radial direction. In other words, of two cylindrical bodies 111 adjacent in the radial direction, the outer end 1122 of the inner cylindrical body 111 does not overlap the inner end 1121 of the outer cylindrical body 111 in the radial direction.

[0019] To incorporate the wound core 100 having such a configuration into the coil 200, two coils 200 are arranged next to each other with their axial lengths parallel and their outer peripheral surfaces in contact, and then one end 102 of the wound core 100 is opened and inserted into the through-holes 201 of each coil 200. That is, the inner end 1121 and outer end 1122 of each cylindrical body 111 of each core block 110 are separated, and the wound core 100 is deformed into an inverted U-shape and inserted into the through-holes 201 of each coil 200, and then returned to its original shape.

[0020] The transformer assembly device 1 according to this embodiment can automate the process of assembling such wound core 100 into the coil 200. The process of assembling such wound core 100 into the coil 200 is performed by separating each core block 110 from the wound core 100 and for each core block 110.

[0021] Fig. 3 is a perspective view of the transformer assembly apparatus 1 according to this embodiment, and Fig. 4 is a front view of the transformer assembly apparatus 1 according to this embodiment. For convenience of explanation, Figs. 3 and 4 omit illustration of part of the transformer assembly apparatus 1, including upper roller members 50 and lower roller members 60, which will be described later.

[0022] The transformer assembly apparatus 1 according to this embodiment includes a frame 90, which is fitted with mounting tables 10, 10 on which two coils 200 are placed, a position adjustment mechanism 80 that finely adjusts the position of the coil 200 on the mounting table 10 left and right and front and back, a moving mechanism 20 that holds and moves the core block 110, a guide member 30 that guides the insertion of the wound core 100 into the coil 200, a drive mechanism 31 that moves the guide member 30 up and down and left and right, and a control unit 40 that controls the drive of the moving mechanism 20, the drive mechanism 31, and the position adjustment mechanism 80.

[0023] The frame 90 extends in the vertical direction and includes four columns 91 arranged to form a rectangle in plan view (the front right column 91 is not shown in FIG. 3). The columns 91 are connected at their upper ends by upper cross members 92 and at their lower ends by lower cross members 93.

[0024] The upper-end horizontal member 92 is bridged between the columns 91 corresponding to each other in the left-right direction and between the columns 91 corresponding to each other in the front-rear direction. Similarly to the upper-end horizontal member 92, the lower-end horizontal member 93 is bridged between the columns 91 corresponding to each other in the left-right direction and between the columns 91 corresponding to each other in the front-rear direction. In other words, the four columns 91 are connected by the upper-end horizontal member 92 and the lower-end horizontal member 93.

[0025] Two mounting tables 10 are provided in the middle of the frame 90 in the vertical direction. Each mounting table 10 has a thick plate shape and is provided so that the thickness direction is the vertical direction. The two mounting tables 10 are arranged at a predetermined interval in the left-right direction and are arranged side by side on the same plane. Each mounting table 10 has a rectangular cutout 101 (see FIG. 5) formed in the edge portion facing the other mounting table 10. In other words, of the two mounting tables 10, the left mounting table 10 is approximately C-shaped in plan view, and the right mounting table 10 is approximately inverted C-shaped in plan view. In plan view, the size of the cutout 101 is approximately the same as the size of the through hole 201 of the coil 200.

[0026] When assembling the wound core 100 into the coil 200, as described above, the two coils 200 are placed side by side on the two mounting tables 10, with their axial lengths aligned vertically and their outer circumferential surfaces in contact with each other. At this time, the position adjustment mechanism 80 finely adjusts the position of the coil 200.

[0027] The position adjustment mechanism 80 includes a clamping unit 82 that clamps each coil 200 placed on the mounting table 10 from behind, a guide rail 83 that extends in the left-right direction and guides the movement of the clamping unit 82, and a servo motor (not shown) that moves the clamping unit 82 left-right and front-back along the guide rail 83. The clamping unit 82 is engaged with the guide rail 83 so as to be slidable on the guide rail 83.

[0028] When two coils 200 are placed on the two mounting tables 10, each clamping unit 82 clamps the inner and outer surfaces of the coil 200, and the control unit 40 controls the servo motor to move the clamping unit 82 so that the position of the through hole 201 of the coil 200 is aligned with the notch 101 of the mounting table 10, i.e., so that the through hole 201 of the coil 200 is positioned directly above the notch 101. The position adjustment mechanism 80 has a handle 81 for manually moving the clamping portion 82, and the operator may fine-tune the position of the coil 200 by appropriately operating the handle 81.

[0029] The moving mechanism 20 includes a gripping portion 21 (holding member) that grips one iron core block 110, a guide portion 23 that guides the gripping portion 21 in the vertical direction, a connecting portion 22 that connects the gripping portion 21 to the guide portion 23, and a servo motor (not shown) that moves the gripping portion 21 up and down along the guide portion 23.

[0030] The gripping portion 21 is approximately hook-shaped and is arranged above the mounting table 10. It grips the portion of the core block 110 that is related to the other end 101 opposite to one end 102 of the wound core 100, i.e., the end opposite to the end where the overlapping portion 112 is formed, and descends from above a pair of adjacent coils 200 toward the coils 200 until the core block 110 is inserted into the coils 200.

[0031] The guide part 23 is provided behind the mounting table 10 and has a round bar 231 extending in the vertical direction and holding bars 232 provided on the left and right sides of the round bar 231 and extending in the vertical direction. The two holding bars 232 are parallel to each other and fixed to the frame 90. The round bar 231 is parallel to the holding bar 232, and both ends are held by the holding bars 232 so as to be rotatable around their axes. In addition, a thread root is formed helically on the outer circumferential surface of the round bar 231 along the length of the round bar 231.

[0032] The connecting part 22 is shaped like a square bar, with the grip part 21 attached to the underside of one end and an engagement hole 221 formed in the other end for engaging with a round bar 231. The engagement hole 221 passes through the connecting part 22 in the vertical direction, and a thread is formed on the circumferential surface of the engagement hole 221 for threading into the thread root of the round bar 231. In other words, the round bar 231 is fitted into the engagement hole 221 of the connecting part 22, and the thread of the engagement hole 221 threads into the thread root of the round bar 231.

[0033] The control unit 40 drives the servo motor to rotate the round bar 231. When the round bar 231 rotates forward or backward, the connecting part 22 moves in the axial direction of the round bar 231, i.e., upward or downward. This causes the gripping part 21 to move up or down.

[0034] In addition, the moving mechanism 20 has a handle 233 for manually moving the gripping portion 21 (connecting portion 22), and the operator can also move the gripping portion 21 (connecting portion 22) in the vertical direction by appropriately operating the handle 233.

[0035] Fig. 5 is a schematic diagram illustrating the main parts of the transformer assembly apparatus 1 according to this embodiment. Fig. 5 shows the positional relationship between the gripping part 21 of the moving mechanism 20, the mounting table 10, and the guide member 30, and for ease of explanation, shows the coil 200 in a vertical cross section, with the core block 110 being gripped by the gripping part 21 above the coil 200.

[0036] As shown in FIGS. 3 to 5, below the table 10, a guide member 30 and a drive mechanism 31 for moving the guide member 30 up and down and left and right are provided.

[0037] The guide member 30 has two guide portions, 30a and 30b. The guide portions 30a and 30b can be moved up and down and left and right by a drive mechanism 31. The guide portions 30a and 30b are made of rectangular metal plates extending in the axial direction of the coil 200, i.e., the up and down direction. The guide portions 30a and 30b are arranged opposite each other in the left and right direction. More specifically, the guide portion 30a is arranged directly below the notch 101 of one of the mounting tables 10, and the guide portion 30b is arranged directly below the notch 101 of the other mounting table 10.

[0038] Therefore, when guide portion 30a and guide portion 30b are moved up and down by drive mechanism 31, they are inserted into and removed from each coil 200. That is, guide portion 30a and guide portion 30b move upward through notch 101 of each mounting table 10 and through hole 201 of coil 200 (see dashed arrows in FIG. 5). That is, guide portion 30a and guide portion 30b can move upward from the standby position shown in FIG. 5 to a position (hereinafter referred to as the uppermost position) where their leading ends come out of the upper end surface of coil 200, passing through notch 101 of mounting table 10 and through hole 201 of coil 200.

[0039] The drive mechanism 31 has a holder 33a that holds the lower end of the guide portion 30a, and a holder 33b that holds the lower end of the guide portion 30b. The drive mechanism 31 also includes a guide rail 32 that extends in the left-right direction and guides the movement of the holder 33a (guide portion 30a) and the holder 33b (guide portion 30b), a handle 31a that moves the holder 33a left and right along the guide rail 32, and a handle 31b that moves the holder 33b left and right along the guide rail 32. The drive mechanism 31 also includes an upward movement mechanism 34a that moves the holder 33a up and down, and an upward movement mechanism 34b that moves the holder 33b up and down.

[0040] The holding portion 33a and the holding portion 33b are engaged with the guide rail 32 so as to be slidable on the guide rail 32. For example, the control portion 40 can move the holding portion 33a left and right along the guide rail 32, and the holding portion 33b can move left and right along the guide rail 32, by appropriately controlling a servo motor (not shown) for rotating the handles 31a and 31b.

[0041] The upward movement mechanism 34a is provided rearward of the guide unit 30a and has a configuration similar to that of the guide unit 23. That is, the upward movement mechanism 34a has a spiral thread formed on its outer circumferential surface in the longitudinal direction, and includes a round bar 341a extending in the vertical direction, and holding bars 342a provided parallel to the round bar 341a on both the left and right sides of the round bar 341a. The round bar 341a is held at both ends by the two holding bars 342a so as to be rotatable around its axis.

[0042] Similarly to the upper movement mechanism 34a, the upper movement mechanism 34b has a spiral thread formed on its outer circumferential surface in the lengthwise direction, and includes a round bar 341b extending in the vertical direction and holding bars 342b provided on the left and right sides of the round bar 341b in parallel with the round bar 341b. The round bar 341b is held at both ends by the two holding bars 342b so as to be rotatable around its axis.

[0043] The holding portion 33a has a hollow rectangular shape in a plan view, and the guide portion 30a is attached to the outer surface of the side wall on the holding portion 33b side. The holding portion 33a also has a through-hole (not shown) with a thread that screws into the thread root of the round rod 341a of the upward movement mechanism 34a, and the round rod 341a is fitted into the through-hole of the holding portion 33a.

[0044] The holding portion 33b has a hollow rectangular shape in a plan view, and the guide portion 30b is attached to the outer surface of the side wall on the holding portion 33a side. The other configurations of the holding portion 33b are the same as those of the holding portion 33a, so detailed explanations will be omitted.

[0045] The control unit 40 drives a servo motor (not shown) to rotate the round bar 341a, causing the round bar 341a to rotate forward or backward, thereby moving the holding portion 33a (guide portion 30a) in the axial direction of the round bar 341a, i.e., upward or downward. In addition, the control unit 40 drives a servo motor (not shown) to rotate the round bar 341b, causing the round bar 341b to rotate forward or backward, thereby moving the holding portion 33b (guide portion 30b) in the axial direction of the round bar 341b, i.e., upward or downward.

[0046] Furthermore, the transformer assembly apparatus 1 according to this embodiment includes upper roller members 50 disposed above the mounting table 10 and lower roller members 60 disposed below the mounting table 10 .

[0047] The upper roller members 50 are disposed directly above each coil 200, and the two upper roller members 50 are attached to the frame 90 at a predetermined distance so as to face each other in the left-right direction. Each upper roller member 50 has a roller portion with a rotation axis parallel to the axial direction of the core block 110. The two upper roller members 50 are configured to be movable in directions toward and away from each other, i.e., left-right, as well as up-down and front-back directions, by the control unit 40. The two upper roller members 50 move away from each other inside the core block 110, separating both ends 1121, 1122 of the core block 110. Additionally, the two upper roller members 50 push against the left and right sides of the core block 110 outside the core block 110, bringing both ends 1121, 1122 of the core block 110 closer together.

[0048] In detail, when the two upper roller members 50 move in a direction separating them from each other, the roller portion of the left upper roller member 50 comes into contact with the inner surface of the iron core block 110 and pulls it to the left, and the roller portion of the right upper roller member 50 comes into contact with the inner surface of the iron core block 110 and pulls it to the right, causing both ends 1121, 1122 of the iron core block 110 to separate from each other and opening the overlapping portion 112.

[0049] Furthermore, when the two upper roller members 50 move in a direction approaching each other, the roller portion of the left upper roller member 50 comes into contact with the outer peripheral surface of the iron core block 110 and urges it to the right, and the roller portion of the right upper roller member 50 comes into contact with the outer peripheral surface of the iron core block 110 and urges it to the left, causing both ends 1121, 1122 of the iron core block 110 to overlap.

[0050] The two lower roller members 60 are disposed directly below each coil 200, and are attached to the frame 90 at a predetermined distance between the guide portions 30a and 30b so that the two lower roller members 60 face each other in the left-right direction. Each lower roller member 60 has a roller portion with a rotation axis that is parallel to the axial direction of the iron core block 110. The two lower roller members 60 are configured to be movable in the up-down direction, i.e., in the direction toward and away from the iron core block 110, by the control portion 40.

[0051] Fig. 6 is a flowchart illustrating the process of incorporating the wound core 100 into the coil 200 in the transformer assembly apparatus 1 according to this embodiment, and Figs. 7 to 9 are explanatory diagrams illustrating the process of incorporating the wound core 100 into the coil 200 in the transformer assembly apparatus 1 according to this embodiment. The process of incorporating the wound core 100 into the coil 200 is performed by repeating the process of inserting the coil 200 into each core block 110 shown in Figs. 7A to 9I.

[0052] For ease of explanation, the mounting tables 10 are not shown in Figures 8 and 9. For ease of explanation, the following description will start from a state in which two coils 200 are mounted adjacent to each other on two mounting tables 10 and fine adjustment of their positions is completed.

[0053] First, one core block 110 associated with the innermost (first) position in the wound core 100 is gripped by the gripping unit 21. Specifically, the end 113 of the core block 110 opposite the overlapping portion 112 is gripped by the gripping unit 21. The control unit 40 then drives the servo motor to rotate the round bars 341a and 341b, thereby moving the guide portions 30a and 30b to their uppermost positions (see FIG. 7A). The guide portions 30a and 30b pass through the notches 101 in the mounting table 10 and the through-holes 201 in the coil 200 and move to their uppermost positions.

[0054] At this time, the overlapping portion 112 of the core block 110 is opened (step S101). As described above, the control unit 40 appropriately controls the two upper roller members 50 to position them inside the core block 110 and then move them in directions separating them from each other, whereby the roller portions of the upper roller members 50 rotate and both end portions 1121, 1122 of the core block 110 are separated from each other, and the core block 110 is deformed into an inverted U-shape.

[0055] In this state, with the overlapping portions 112 of the cylindrical bodies 111 open and the inner end portions 1121 and outer end portions 1122 spaced apart, the control unit 40 drives the servo motor to reversely rotate the round bar 231, thereby lowering the gripping portion 21 (iron core block 110) and the two upper roller members 50. After the iron core block 110 has lowered to an appropriate position, the control unit 40 moves the upper roller members 50 left and right as appropriate to hook both end portions 1121, 1122 of the iron core block 110 onto the guide portions 30a, 30b (step S102).

[0056] At this time, all of the inner ends 1121 are hooked onto the tip of the guide portion 30a that has come out from the upper end surface of the coil 200, and all of the outer ends 1122 are hooked onto the tip of the guide portion 30b that has come out from the upper end surface of the coil 200 (see Figure 7B).

[0057] That is, the inner end 1121 of each cylindrical body 111 is held in contact with the outer surface of guide portion 30a, and the outer end 1122 of each cylindrical body 111 is held in contact with the outer surface of guide portion 30b (see the dashed circle in Figure 7B), and guide portion 30a and guide portion 30b hold the inner end 1121 and outer end 1122 of each cylindrical body 111 of the iron core block 110 in a mutually spaced state (hereinafter referred to as the spaced state).

[0058] Thereafter, the core block 110 is inserted into the through-hole 201 of the coil 200 (step S103). More specifically, the control unit 40 drives the servo motor to lower the gripping unit 21 (core block 110), and simultaneously drives the servo motor to lower the guide units 30a and 30b. That is, when the gripping unit 21 (core block 110) is lowered, the guide units 30a and 30b are also lowered while maintaining the separation between the end portions 1121 and 1122 of the cylindrical body 111 (see FIG. 7C). This allows the core block 110 to be inserted into the through-hole 201 of the coil 200.

[0059] At this time, the control unit 40 appropriately controls the two upper roller members 50 to position them outside the iron core block 110 and then move them in a direction toward each other, thereby preventing the iron core block 110 from hitting the edge of the through hole 201 of the coil 200 and making it easier to insert the iron core block 110 into the through hole 201 of the coil 200.

[0060] The lowering of the gripping portion 21 (core block 110) and the guide portions 30a, 30b continues until the end portion 113 of the core block 110 opposite the overlapping portion 112 abuts against the upper end surface of the coil 200. When the end portion 113 of the core block 110 abuts against the upper end surface of the coil 200, the insertion of the core block 110 into the through-hole 201 of the coil 200 is completed, and the control portion 40 stops the lowering of the gripping portion 21.

[0061] Thereafter, the control unit 40 drives the servo motor to rotate the round rods 341a and 341b, thereby further lowering the guide portions 30a and 30b, and releasing the hold on the inner end portion 1121 and the outer end portion 1122.

[0062] First, the control unit 40 releases the hold of the inner end 1121 (step S104). That is, when the insertion of the coil 200 of the iron core block 110 into the through-hole 201 is completed, the control unit 40 first rotates the round bar 341a to lower the guide portion 30a that has been holding the inner end 1121, and separates the guide portion 30a from the inner end 1121 (see FIG. 8D). When the hold of the guide portion 30a is released in this way, a restoring force is applied to the inner end 1121.

[0063] At this time, in order to easily and reliably restore the inner end portion 1121 and to ensure space within the through hole 201 in preparation for the insertion of the next second core block 110, the guide portion 30a presses the core block 110 against the inner surface of the left coil 200 (step S105).

[0064] That is, as shown in Figure 8E, the control unit 40 rotates the round bar 341a to raise the guide part 30a inside the left coil 200, then moves it toward the core block 110, and presses the outer surface of the core block 110 related to the inner end 1121 against the inner surface of the left coil 200.

[0065] Next, in order to facilitate the restoration of the inner end portion 1121 and to adjust the shape of the wound core 100 after the work of incorporating the inner end portion 1121 into the coil 200 is completed, the inner end portion 1121 is bent toward the coil 200 (step S106).

[0066] More specifically, the control unit 40 appropriately controls the left lower roller member 60 of the two lower roller members 60 to move it upward, causing the roller portion of the lower roller member 60 to rotate and the inner end portion 1121 to be pressed against the lower end surface of the left coil 200 and bend (see FIG. 8F). This state is maintained until the inner end portion 1121 is released during the operation of inserting the coil 200 into the second core block 110.

[0067] Subsequently, the control unit 40 releases the outer end 1122 from its hold (step S107). That is, the control unit 40 rotates the round bar 341b to lower the guide unit 30b that has been holding the outer end 1122, and separates the guide unit 30b from the outer end 1122 (see FIG. 9G). When the hold of the guide unit 30b is released in this manner, a restoring force is applied to the outer end 1122.

[0068] At this time, in order to easily and reliably restore the outer end portion 1122 and to ensure space within the through hole 201 in preparation for the insertion of the next second core block 110, the guide portion 30b presses the core block 110 against the inner surface of the right coil 200 (step S108).

[0069] That is, as shown in Figure 9H, the control unit 40 rotates the round bar 341b to raise the guide part 30b inside the right coil 200, then moves it toward the core block 110, and presses the outer surface of the core block 110 relating to the outer end 1122 against the inner surface of the right coil 200.

[0070] Next, in order to facilitate the restoration of the outer end 1122 and to arrange the shape of the wound core 100 after the work of incorporating the outer end 1122 into the coil 200 is completed, the outer end 1122 is bent toward the coil 200 (step S109).

[0071] More specifically, the control unit 40 appropriately controls the right-hand lower roller member 60 of the two lower roller members 60 to move it upward toward the core block 110, causing the roller portion of the lower roller member 60 to rotate and the outer end 1122 to be pressed against the lower end surface of the right-hand coil 200 and bend (see FIG. 9I). This state is maintained until the outer end 1122 is released from its hold during the operation of inserting the coil 200 into the second core block 110.

[0072] Once the coil 200 of the innermost (first) core block 110 in the wound core 100 has been inserted into the through-hole 201 in the manner described above, the steps of Figures 7A to 9I are similarly carried out on the second innermost core block 110.

[0073] At this time, the control unit 40 appropriately operates the handles 31a and 31b in accordance with the expansion of the diameter of the core block 110, and the holding portions 33a and 33b are appropriately moved left and right in directions in which they move away from each other.

[0074] Furthermore, when inserting the coil 200 into the second core block 110, the two lower roller members 60 press the inner end 1121 and outer end 1122 of the first core block 110, together with the inner end 1121 and outer end 1122 of the second core block 110, against the lower end surface of the coil 200.

[0075] As described above, during the operation of inserting the coil 200 into the second core block 110, the left lower roller member 60 continues to press the inner end 1121 of the first core block 110 against the bottom end surface of the left coil 200 until the hold on the inner end 1121 is released. When the hold on the inner end 1121 of the second core block 110 is released, the left lower roller member 60 is controlled by the control unit 40 to move downward away from the inner end 1121 of the first core block 110, and then the left lower roller member 60 moves upward again, pressing the inner end 1121 of the first core block 110 and the inner end 1121 of the second core block 110 against the bottom end surface of the left coil 200 to bend them.

[0076] Furthermore, during the operation of inserting the coil 200 into the second core block 110, the right-side lower roller member 60 continues to press the outer end 1122 of the first core block 110 against the bottom end surface of the right-side coil 200 until the hold on the outer end 1122 is released. When the hold on the outer end 1122 of the second core block 110 is released, the right-side lower roller member 60 is controlled by the control unit 40 to move downward away from the outer end 1122 of the first core block 110, and then the right-side lower roller member 60 moves upward again, pressing the outer end 1122 of the first core block 110 and the outer end 1122 of the second core block 110 against the bottom end surface of the right-side coil 200 to bend them.

[0077] This process is repeated for all the core blocks 110 that make up the wound core 100, and this completes the process of assembling the wound core 100 into the coil 200.

[0078] As described above, the transformer assembly device 1 of this embodiment can automate the process of assembling the wound core 100 into the coil 200 by lowering each core block 110 using the gripping portion 21 (moving mechanism 20) and guiding the insertion of the core block 110 into the inside of the coil 200 using the guide portion 30a and the guide portion 30b (upper moving mechanism 34a and the upper moving mechanism 34b).

[0079] Furthermore, the transformer assembly apparatus 1 according to this embodiment uses the guide portions 30a and 30b for such automation, and therefore the configuration of the apparatus can be simplified and the operation of the apparatus can be simplified.

[0080] Furthermore, as described above, in the transformer assembly apparatus 1 according to this embodiment, the guide portions 30a and 30b have a rectangular plate shape extending in the vertical direction. Therefore, the space occupied by the guide portions 30a and 30b within the through hole 201 of the coil 200 is small, and the steps of FIGS. 7A to 9I can be easily performed for all of the core blocks 110 of the wound core 100, that is, for the outermost core block 110 of the wound core 100.

[0081] Furthermore, as described above, in the transformer assembly apparatus 1 of this embodiment, when the gripping portion 21 (iron core block 110) is lowered, the guide portions 30a and 30b also lower while maintaining the separation between the two end portions 1121, 1122 of the cylindrical body 111, making it easier to insert the coil 200 of the iron core block 110 into the through hole 201.

[0082] Furthermore, in the transformer assembly apparatus 1 according to this embodiment, as described above, when insertion of the coil 200 of the core block 110 into the through hole 201 is completed, the control unit 40 first moves the guide portion 30a, which has been holding the inner end portion 1121, away from the inner end portion 1121, and then moves the guide portion 30b, which has been holding the outer end portion 1121, away from the outer end portion 1122. This makes it possible to easily return both ends 1121, 1122 of the core block 110 to the same overlapping state as before separation from the wound core 100.

[0083] Furthermore, in the transformer assembly apparatus 1 according to this embodiment, when both ends 1121, 1122 of the core block 110 are hooked onto the guide portions 30a, 30b, as described above, the two upper roller members 50 positioned inside the core block 110 are moved in directions separating them from each other, separating both ends 1121, 1122 of the core block 110 from each other and opening the overlapping portion 112. This allows the process of hooking both ends 1121, 1122 of the core block 110 onto the guide portions 30a, 30b to be carried out quickly and easily.

[0084] In the above, an example has been described in which the control unit 40 rotates the handles 31a and 31b to move the holding units 33a and 33b left and right along the guide rail 32, but the present invention is not limited to this. For example, the operator may operate the handle 31a as appropriate to move the holding unit 33a left and right along the guide rail 32, and the operator may operate the handle 31b as appropriate to move the holding unit 33b left and right along the guide rail 32.

[0085] In the above description, the guide portions 30a and 30b are described as having a rectangular plate shape extending in the vertical direction, but the present invention is not limited to this and may be, for example, rod-shaped. Further, recesses for positioning both ends 1121 and 1122 of the core block 110 may be provided at the tip ends of the guide portions 30a and 30b.

[0086] Furthermore, in the above, we have described a case where the upper roller member 50 is used to separate both ends 1121, 1122 of the iron core block 110 from each other and open the overlapping portion 112, and the lower roller member 60 is used to press and bend both ends 1121, 1122 of the iron core block 110 toward the lower end surface of the coil 200, but this is not limited to this, and such work may be performed manually by an operator instead of using the upper roller member 50 and the lower roller member 60.

[0087] The technical features (constituent elements) described in this embodiment can be combined with each other, and by combining them, new technical features can be conceived. The embodiments disclosed herein are to be considered in all respects as illustrative and not restrictive. The scope of the present invention is defined by the claims, not by the above meaning, and is intended to include all modifications within the meaning and scope of the claims.

[0088] The matters described in the embodiments can be combined with each other. Furthermore, the independent claims and dependent claims described in the claims can be combined with each other in any and all combinations, regardless of the reference format. Furthermore, while the claims use a format in which a claim references two or more other claims (multiple claim format), this is not limited to this format. A multiple claim (multi-multi claim) that references at least one other multiple claim may also be used. [Explanation of symbols]

[0089] 1: transformer assembly device, 20: moving mechanism, 21: gripping portion (holding member), 30: guide member, 30a: guide portion, 30b: guide portion, 40: control portion, 50: upper roller member, 60: lower roller member, 100: wound core (iron core), 110: core block, 111: cylindrical body, 112: overlapping portion, 200: coil, 300: transformer, 1121: inner end portion, 1122: outer end portion

Claims

1. A transformer assembling method for assembling a transformer including an iron core in which a plurality of cylindrical bodies whose both ends overlap in the circumferential direction are overlapped in the radial direction, and a pair of coils arranged adjacent to each other, comprising: an ascending step in which each of the two guide portions ascends from below the pair of coils while passing through the inside of each coil; a hooking step of pulling both ends of a predetermined number of cylindrical bodies in a direction away from each other and hooking them onto the tip ends of each guide part; an insertion step in which the cylindrical body of the unit number is lowered together with the two guide parts and inserted into the coil in a state in which the both end parts are hooked onto the tip end parts of each guide part; a separating step in which, when the insertion of the unit number of cylindrical bodies into the coil is completed, the two guide parts move in a direction away from the coil and are separated from the unit number of cylindrical bodies; Transformer assembly method to perform.

2. In the unit number of cylindrical bodies, the overlapping portions at both ends of each cylindrical body are offset in one direction in the circumferential direction, In the hooking step, The inner end of each cylindrical body is hooked onto one guide portion, and the outer end is hooked onto the other guide portion. In the separating step, 2. The transformer assembling method according to claim 1, wherein the one guide portion is separated from the unit number of cylindrical bodies before the other guide portion is separated from the unit number of cylindrical bodies.

3. In the hooking step, 2. The transformer assembling method according to claim 1, wherein the unit number of cylindrical bodies are pulled in directions in which two portions of the cylindrical bodies that face each other in the direction in which the two end portions move together move apart from each other.

4. In the insertion step, 2. The transformer assembling method according to claim 1, wherein the cylindrical bodies inserted into the coil are pushed in a direction in which two portions of the cylindrical bodies facing each other in the direction in which the two ends of the cylindrical bodies approach each other.

5. In the separating step, Each guide portion returns to the inside of the coil after being separated from the cylindrical bodies of the unit number, and presses the cylindrical bodies of the unit number toward the other guide portion, 2. The transformer assembling method according to claim 1, wherein each end of said unit number of cylindrical bodies is bent toward the lower end surface of said coil.

6. A transformer assembling device for assembling a transformer in which an iron core, in which a plurality of cylindrical bodies each having both ends overlapping in the circumferential direction and overlapping in the radial direction, is inserted into a pair of adjacent coils, Two guide parts that move up and down through the inside of each coil, a holding member for holding a predetermined number of cylindrical bodies above the pair of coils; a control unit that lowers the holding member and the two guide parts together in a state in which both end portions of the cylindrical body of the unit number are hooked onto the tip portions of each guide part, and inserts the cylindrical body of the unit number into the coil, The control unit moves the two guide parts away from the coil when the insertion of the unit number of cylindrical bodies into the coil is completed, thereby separating the two guide parts from the unit number of cylindrical bodies.

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