Transformer and transformer assembly method

Abstract

To provide a transformer in which an iron core and a coil can be assembled easily and productivity can be improved, and to provide a transformer assembling method.SOLUTION: In a transformer in which two iron cores 100 in which a plurality of rectangular cylindrical bodies 111 bent in a rectangular cylindrical shape overlap in a thickness direction are inserted into a coil 200 such that long side portions 120 are adjacent to each other, both end portions 11211122 of each rectangular cylindrical body 111 in a bending direction are butted against each other, and each iron core 100 has a portion 112 of each rectangular cylindrical body 111 on one end side of the long side portion 120.SELECTED DRAWING: Figure 2

Description

[Technical Field]

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

[0002] The manufacturing process for transformers includes, for example, a step of inserting an iron core, which is made up of multiple rectangular cylindrical bodies bent and stacked in the thickness direction, into a coil in an open state with both ends of the bend spaced apart from each other. In the process of assembling such an iron core into a coil, the coil has traditionally been laid on its side, and workers have divided the iron core into multiple sections and inserted the sections into the coil from the side.

[0003] In response to this, for example, Patent Document 1 discloses a technique for automating the process of incorporating the iron core into the coil, thereby increasing the productivity of transformers. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 10-135058 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in Patent Document 1, the iron core is divided into a plurality of sections and then inserted into the coil, as in the conventional art, and it cannot be said that productivity of transformers has been sufficiently improved.

[0006] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a transformer and a method of assembling the transformer in which the assembly of the iron core and the coil is simple and productivity can be improved. [Means for solving the problem]

[0007] The transformer of the present invention is a transformer in which two iron cores, each made of a plurality of rectangular tubes bent into a rectangular tube shape and overlapping in the thickness direction, are inserted into a coil with their long sides adjacent to each other, and both ends of each rectangular tube in the bending direction are butted together, and each iron core has the butt portion of each rectangular tube on one end side of the long sides.

[0008] The transformer assembly method of the present invention is a method for assembling a transformer in which two iron cores, each made of a plurality of rectangular cylinders bent into a rectangular cylinder shape and with both ends in the bending direction butted together, overlap in the thickness direction and are inserted into a coil so that one of the long sides is adjacent to each other.The two iron cores, each having a butting portion of each rectangular cylinder on one end side of one of the long sides, are placed with the one end side facing up so that one of the long sides is adjacent to each other, and a tensile force is applied to each of the other long sides of the two iron cores in a direction that moves them away from each other to open the butting portion of each rectangular cylinder.The coil is fitted into one of the long sides of the two iron cores from the open side of each iron core, and the tensile force applied to the other long side of each iron core is released. [Effects of the Invention]

[0009] According to the present invention, a transformer and a method for assembling the transformer are provided that allow for easy assembly of the iron core and the coil, thereby improving productivity. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view illustrating an example of a transformer according to an embodiment of the present invention. [Figure 2] FIG. 2 is a schematic side view showing the configuration of a wound core according to the present embodiment. [Figure 3] 4A to 4C are explanatory views illustrating the process of incorporating coils into two wound cores in the assembly of the transformer according to the present embodiment. [Figure 4] FIG. 10 is an explanatory diagram illustrating a range in which a butt portion can be formed in the transformer according to the present embodiment. [Figure 5] FIG. 10 is an explanatory diagram illustrating a range in which a butt portion can be formed in the transformer according to the present embodiment. [Figure 6]FIG. 10 is a schematic side view of a wound core showing another example of an abutting portion of a wound core in a transformer. [Figure 7] FIG. 10 is a schematic side view of a wound core showing another example of an abutting portion of a wound core in a transformer. 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 according to this embodiment. In FIG. 1, reference numeral 300 denotes a transformer. The transformer 300 is configured by assembling two adjacent wound cores 100 (iron cores) and one coil 200. For example, each coil 200 has a hollow, rounded rectangular shape in axial cross section, and each wound core 100 has a rectangular shape in axial cross section.

[0013] Figure 2 is a schematic side view showing the configuration of a wound core 100 according to this embodiment. For ease of explanation, two wound cores 100 are shown in Figure 2, with the coil 200 indicated by a two-dot chain line. The view within the ellipse in Figure 2 is an enlarged view of the portion of the wound core 100 enclosed by the dashed ellipse.

[0014] Generally, a wound core 100 is obtained by stacking a predetermined number of thin, rectangular core elements, each formed by cutting a hoop material such as a silicon steel strip to a predetermined length in the longitudinal direction, and then bending the stack to form a rectangular axial cross section. In this process, the length between both ends of each core element, i.e., the length of each rectangular core element (hereinafter referred to as a rectangular cylinder) 111 in axial cross section in the bending direction during the bending process, is longer for the outermost rectangular cylinders 111.

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

[0016] That is, in each wound core 100, multiple core blocks 110 are stacked on the same axis in the thickness direction, and multiple rectangular cylinders 111 are stacked on the same axis in the thickness direction in each core block 110. In each wound core 100, of two core blocks 110 adjacent to each other in the thickness direction, the outer peripheral surface of the inner core block 110 contacts the inner peripheral surface of the outer core block 110, and of two rectangular cylinders 111 adjacent to each other in the thickness direction, the outer peripheral surface of the inner rectangular cylinder 111 contacts the inner peripheral surface of the outer rectangular cylinder 111.

[0017] Each wound core 100 has two long side portions formed by the long side portions of each rectangular cylindrical body 111 overlapping in the thickness direction, and two short side portions formed by the short side portions of each rectangular cylindrical body 111 overlapping in the thickness direction and connected to the long side portions.

[0018] As described above, the transformer 300 is configured by arranging two wound cores 100 side by side and incorporating them into one coil 200. In the following, of the two long sides of each wound core 100, the long side adjacent to the long side of the other wound core 100 will be referred to as long side 120, and the short side connected to one end of long side 120 will be referred to as short side 130.

[0019] In other words, in the transformer 300, the long sides 120 of the two wound cores 100 are adjacent to each other, and these two long sides 120 are inserted into the through-hole 201 of the coil 200 (see FIG. 1).

[0020] Each wound core 100 has, at one end 101 in the longitudinal direction, a butt joint 112 where both ends 1121, 1122 of each rectangular tubular body 111 are butted together. In other words, in each wound core 100, a butt joint 112 of each rectangular tubular body 111 constituting the wound core 100 (hereinafter also referred to as the butt joint 112 of the wound core 100) is formed at or near a corner 140 connecting the long side 120 and short side 130. At the butt joint 112 of each rectangular tubular body 111, the end 1121 on the short side 130 side of the wound core 100 and the end 1122 on the long side 120 side are butted together.

[0021] In each wound core 100, the butt joints 112 of the multiple rectangular tubes 111 are generally formed in a straight line. The example in Fig. 2 illustrates a case in which the butt joints 112 of each wound core 100 are formed in a straight line in a direction intersecting the short side portion 130 at the boundary between the corner portion 140 and the short side portion 130.

[0022] More specifically, as shown in FIG. 2, all of the butt joints 112 of each wound core 100 are formed in a row at position P1 on the short side 130, which is separated from the outer surface of the long side 120 (see the dashed line in FIG. 2) by the thickness L of the wound core 100.

[0023] That is, in the transformer 300 according to this embodiment, the butt joint 112 of each rectangular tube 111 is formed on the short side portion 130 (or corner portion 140) of each wound core 100 at a position where it intersects with a plane including the inner surface of the long side portion of the innermost rectangular tube 111 that constitutes the long side portion 120.

[0024] As a result, in the transformer 300 of this embodiment, the end faces of both end portions 1121, 1122 of each rectangular tube 111 are arranged in the same plane as the inner surface of the long side portion of the innermost rectangular tube 111 that constitutes the long side portion 120, and are linear when viewed in the axial direction (see Figure 2).

[0025] 3 is an explanatory diagram illustrating the process of incorporating the coil 200 into two wound cores 100 in the assembly of the transformer 300 according to this embodiment. The process of incorporating the coil 200 into the wound core 100 is performed in the order shown in FIGS. 3A to 3C.

[0026] First, two wound cores 100 are placed on a mounting table (not shown) so that their long sides 120 are adjacent to each other, for example, so that the outer surfaces of the long sides 120 abut against each other. At this time, each wound core 100 is placed so that its short side 130 is on top (see FIG. 2). This positions the butt joint 112 of each wound core 100 closer to the other wound core 100. In this state, the lower short side of each wound core 100 is fixed to the mounting table.

[0027] Next, in each wound core 100, the long side 150 facing the long side 120 is pulled in a direction away from the long side 120. That is, a tensile force is applied to each long side 150 of the two wound cores 100 in a direction away from each other. As a result, the short side 130 and the long side 150 move (deform) in a direction away from the long side 120 (in the direction of the arrow in FIG. 3A), and the butt portions 112 (both ends 1121, 1122) of all the rectangular tubes 111 of each wound core 100 are separated (see FIG. 3A).

[0028] As described above, when the butt joints 112 of the cores 100 are separated and the tops of the two cores 100 are opened, buffer material 50 is laid inside each core 100 to prevent malfunctions in the assembled transformer 300 due to collisions between the coils 200 and the cores 100, and also for insulation (see FIG. 3A).

[0029] Next, the coil 200 is fitted onto both long side portions 120 of the two wound cores 100 from the open sides (upper sides) of the two wound cores 100 (see FIG. 3B). As a result, both long side portions 120 of the two wound cores 100 are inserted into the through holes 201 of the coil 200, and one end portion (corner portion 140) of both long side portions 120 passes through the through holes 201 of the coil 200 and exits to the upper side.

[0030] The tension applied to the long side portions 150 of each of the two wound cores 100 is then released. At this time, the restoring force of the wound core 100 (rectangular tubular body 111) itself causes the short side portions 130 and long side portions 150 to return in a direction approaching the long side portion 120 (in the direction of the arrow in FIG. 3C), and both end portions 1121, 1122 of all of the rectangular tubular bodies 111 of each wound core 100 are butted together (see FIG. 3C). Note that after this, an operator may adjust the butt state of both end portions 1121, 1122.

[0031] As described above, in the transformer 300 according to this embodiment, the butt joints 112 of the wound cores 100 are formed at the boundaries between the short side portions 130 and the corner portions 140. Therefore, as shown in FIG. 3 , the butt joints 112 of each wound core 100 are opened, the coil 200 is fitted onto the long side portions 120 of each wound core 100, and then the butt joints 112 of each wound core 100 are returned to their original shape, thereby completing the process of incorporating the coil 200 into the wound core 100.

[0032] As a result, the assembly work of the transformer 300 according to this embodiment can be performed with improved workability and increased productivity compared to the conventional assembly work in which each core block 110 was carried out separately.

[0033] In the above description, an example has been given in which all of the butt joints 112 of each wound core 100 are formed in a row at the boundary between the short side 130 and the corner 140, that is, at position P1 on the short side 130 (or corner 140) separated from the outer surface of the long side 120 by the thickness L of the wound core 100. However, the transformer 300 according to this embodiment is not limited to this, and it is sufficient if each butt joint 112 of each wound core 100 is formed within a range that includes the corner 140 and the vicinity of the corner 140.

[0034] 4 and 5 are explanatory diagrams illustrating the range in which the butt joint 112 can be formed in the transformer 300 according to this embodiment. For ease of explanation, only one wound core 100 is shown schematically in Fig. 4 and 5, and the coil 200 is indicated by a two-dot chain line.

[0035] In the transformer 300 according to this embodiment, the butt portion 112 of the wound core 100 may be formed between a first position, which is near a position P1 on the short side portion 130, and a second position, which is near a position P2 (see FIG. 5) on the long side portion 120 and separated from the outer surface of the short side portion 130 by the thickness L of the wound core 100. FIG. 4 illustrates the wound core 100 in which the butt portion 112 is formed at the first position, and FIG. 5 illustrates the wound core 100 in which the butt portion 112 is formed at the second position. The first position and the second position will be described in detail below.

[0036] 4, when the butt joint 112 is formed at the first position, the butt joint 112 of the innermost rectangular cylinder 111 in the wound core 100 is formed on the short side 130 (position P1) and separated from the outer surface of the long side 120 by the thickness L of the wound core 100. The other rectangular cylinders 111 are formed so that the butt joints 112 of the outermost rectangular cylinders 111 are shifted away from the long side 120 and form a straight line on the short side 130.

[0037] 5, when the butt joints 112 are formed at the second position, each butt joint 112 is formed slightly closer to the other end of the long side 120 than the position P2 in the wound core 100. For example, each butt joint 112 is formed at a position spaced 1 / 3 of the length H of the coil 200 from the end face of the coil 200 near the short side 130 toward the other end of the long side 120.

[0038] In the transformer 300 according to this embodiment, when the butt portions 112 of the wound cores 100 are formed between the first position (see FIG. 4) and the second position (see FIG. 5) as described above, there is no problem in the process of fitting the coils 200 onto both long side portions 120 of the two wound cores 100 (see FIG. 3B) and in the process of adjusting the butt state of the both end portions 1121, 1122 after the process of FIG. 3C, and the above-described effects of the present invention can be achieved.

[0039] For example, if the position of the butt joint 112 of the wound core 100 is too close to the long side 150 on the short side 130, the edge of the through hole 201 of the coil 200 will interfere with the end 1122 on the long side 120 side of the wound core 100, causing an obstruction when fitting the coil 200 onto both long side portions 120 of the two wound cores 100. However, in the transformer 300 according to this embodiment, the butt joint 112 of the wound core 100 is formed in the range from the first position toward the long side 120, so that the process of fitting the coil 200 onto both long side portions 120 of the two wound cores 100 is not obstructed, the work of adjusting the butt joint between the end portions 1121, 1122 is made easier, and the occurrence of such problems can be prevented.

[0040] Furthermore, if the butt joint 112 of the wound core 100 is located too close to the other end of the long side 120, it becomes difficult to reach the butt joint between the two ends 1121, 1122, which reduces workability. In contrast, in the transformer 300 according to this embodiment, the butt joint 112 of the wound core 100 is formed in the range from the second position to one end of the long side 120, so that the butt joint between the two ends 1121, 1122 is not impeded, improving workability in the process of fitting the coil 200 between the long side 120 of the two wound cores 100 and preventing such problems from occurring.

[0041] The transformer 300 according to this embodiment is not limited to the above description. For example, when the butt joints 112 are formed on the long side portions 120 of each wound core 100, the butt joints 112 of the outermost rectangular cylinders 111 may be formed so as to be closer to one end of the long side portions 120. Furthermore, when the butt joints 112 are formed on the long side portions 120 of each wound core 100, the butt joints 112 of the outermost rectangular cylinders 111 may be formed so as to be farther from one end of the long side portions 120.

[0042] (Variation 1) 6 is a schematic side view of the wound core 100, showing another example of the butt joint 112 of the wound core 100 in a transformer 300. For ease of explanation, only two wound cores 100 are shown in FIG. 6, and the coils 200 are indicated by two-dot chain lines for reference.

[0043] In the transformer 300 according to the first modification, the butt joints 112 of the wound cores 100 are shifted slightly from the position P1 toward the outer surface of the long side 120 (see the dotted line in FIG. 6) and formed in a straight line.

[0044] More specifically, in each wound core 100, the butt joint 112 of the innermost rectangular tube 111 is formed at the above-mentioned position P1. Furthermore, the other rectangular tubes 111 are formed so that the butt joint 112 of the outermost rectangular tube 111 is closer to the outer surface of the long side 120. In other words, the other rectangular tubes 111 are formed so that the butt joint 112 of the outermost rectangular tube 111 is closer to the outer surface of the short side 130. For ease of explanation, the position of the butt joint 112 of the wound core 100 shown in Figure 6 will be referred to as the third position below.

[0045] (Variation 2) In the above, an example has been described in which the butt joints 112 of the two wound cores 100 have shapes that correspond to each other, but the transformer 300 according to Modification 2 is not limited to this.

[0046] 7 is a schematic side view of the wound core 100, showing another example of the butt joint 112 of the wound core 100 in a transformer 300. For ease of explanation, only two wound cores 100 are shown in FIG. 7, and the coils 200 are indicated by two-dot chain lines for reference.

[0047] In the transformer 300 according to the second modification, the butt joint 112 of one of the two wound cores 100 is shifted slightly from position P1 toward the long side 150 and formed in a straight line. The butt joint 112 of the other wound core 100 is shifted slightly from position P1 toward the outer surface of the long side 120 (see the dotted line in FIG. 7 ) and formed in a straight line.

[0048] That is, in the transformer 300 according to the second modification, of the two wound cores 100, the butt portion 112 of one wound core 100 is formed at a first position, and the butt portion 112 of the other wound core 100 is formed at a third position.

[0049] In both the transformer 300 of the first and second variants, the distance from the butt portion 112 of one wound core 100 to the corresponding butt portion 112 of the other wound core 100 does not exceed the sum of the thicknesses L of the two wound cores 100 (2L), and is shorter than the inner diameter of the coil 200, making it easy to incorporate the coil 200.

[0050] Furthermore, without being limited to the above description, the butt portions 112 of the two wound cores 100 may be formed at positions related to combinations obtained from the first position, the second position, the third position, position P1, or position P2.

[0051] 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.

[0052] 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]

[0053] 100: wound core (iron core), 110: core block, 111: rectangular cylinder, 112: butt joint, 120, 150: long side, 130: short side, 140: corner, 200: coil, 300: transformer, 1121, 1122: end, H: coil length, L: wound core thickness

Claims

1. A transformer in which two iron cores, each made of a plurality of rectangular cylindrical bodies bent into a rectangular cylindrical shape and overlapping in the thickness direction, are inserted into a coil with their long sides adjacent to each other, Both ends of each rectangular tube are butted together in the bending direction. Each iron core has a butt joint of each rectangular cylindrical body on one end side of the long side.

2. The butt portion of each core is 2. A transformer as described in claim 1, wherein the core is formed between a first position on the short side portion at one end of the long side portion, near a position separated from the outer surface of the long side portion by the thickness of the iron core, and a second position on the long side portion, near a position separated from the outer surface of the short side portion by the thickness of the iron core.

3. When the butt portion is formed at the first position, the iron core is the butt portion of the innermost rectangular cylinder is formed on the short side portion and spaced from the outer surface of the long side portion by the thickness of the iron core, 3. The transformer according to claim 2, wherein the butt joints of the outer rectangular tubes are shifted in a direction away from the long side portions.

4. When the butt portion is formed at the second position, the iron core is 3. The transformer according to claim 2, wherein each butt portion is formed at a position spaced 1 / 3 of the length of the coil from the end face of the coil near the short side toward the other end of the long side.

5. 5. A transformer according to claim 2, wherein each butt portion of at least one of the two iron cores is formed on the short side portion, spaced from the outer surface of the long side portion by the thickness of the iron core.

6. 5. A transformer according to claim 2, wherein the butt joint of at least one of the two cores is formed closer to the outer surface of the short side portion as the core is an outer rectangular cylinder.

7. A method for assembling a transformer in which two iron cores, each made of a plurality of rectangular cylindrical bodies bent into a rectangular cylindrical shape and having both ends in the bending direction butted together, overlap in the thickness direction, are inserted into a coil so that one long side of each iron core is adjacent to the other, The two iron cores each having a butt portion of each rectangular tubular body on one end side of the one long side are placed with the one end side facing up so that the one long side portions are adjacent to each other, A tensile force is applied to each of the other long side portions of the two iron cores in a direction in which they are separated from each other, thereby opening the butted portions of each rectangular cylindrical body; The coil is fitted onto one of the long sides of the two iron cores from the open side of each iron core; The tension applied to the other long side of each iron core is released. Transformer assembly method.

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