Method for integrally grasping, positioning, stacking, and laminating single-batch, uniform-wide sheet materials for transformer core

Abstract

The present invention relates to the field of transformer assembly, and relates in particular to a method for integrally grasping, positioning, stacking, and laminating single-batch, uniform-wide sheet materials for a transformer core. The method comprises the following steps: S1: counting the number of sheet materials of each width and sheet type required for a plurality of cores; S2: shearing a large coil of silicon steel into silicon steel strips of corresponding widths; S3: shearing silicon steel strips of each width into corresponding sheet types, and placing the sheared sheet materials into trays, each batch of sheet materials being separated by a partition plate; S4: using a manipulator to pick up one batch of sheet materials from each tray at a time, placing same at a lamination station, and performing a laminating operation, each lamination station forming a single core column upon completion of the lamination; and S5: transferring the single core column to a subsequent process to complete core assembly. According to the present invention, sheet materials for a plurality of cores are uniformly punched and sheared, so that the production efficiency of transverse cutting can be improved by about 20%; each batch of sheet materials is separated by a partition plate, and a manipulator picks up one batch of sheet materials at a time for lamination, so that core lamination efficiency can be increased by three to four times.

Description

A method for integrally grabbing, positioning, and stacking single-stage wide sheets of transformer core Technical Field

[0001] The invention relates to the field of transformer assembly, and in particular to a method for integrally grabbing, positioning, stacking and laminating single-stage wide sheets of transformer iron core. Background Art

[0002] The transformer core is the core component of the transformer, constructed from laminated silicon steel sheets. Its primary function is to convert and transmit electrical energy. The core not only serves as a medium for electromagnetic conversion but also as a support structure for the coils and the transformer body. To reduce eddy current losses and improve performance, the transformer core is typically constructed from high-resistivity silicon steel sheets, fabricated into core sheets of a specific size, which are then assembled in an overlapping pattern.

[0003] Method 1: batch shearing with manual lamination, and method 2: single-section shearing with machine electric suction lamination. These are the two main methods for current core production. The advantage of method 1 is its high cutting efficiency. The disadvantage is that it requires a lot of people, has low efficiency, is easily affected by human factors, and is prone to quality stability. Long-term repetitive labor may cause worker fatigue, thus affecting production efficiency and quality. The advantage of method 2 is that it requires less people and is easy to ensure quality. The disadvantage is low cutting efficiency. The sheet needs to be changed after each sheet is cut, which greatly reduces the cutting efficiency. The existing machine electric suction lamination absorbs one or several sheets at a time. During the lamination process, the same level needs to be stacked multiple times to complete. There is also the problem of low lamination efficiency.

[0004] Patent publication number CN112382502A discloses an automatic transformer core stacking production line that achieves automatic stacking of transformer cores. However, during the implementation process, the methods for achieving effects such as positioning and quantity control are relatively complex, and the equipment cost is high. Patent publication number CN102896444A discloses an automatic laminating machine with a disc-type structure that can achieve automatic lamination and forming of sheet materials. However, it adopts a one-sheet-one-stack method at a time, which makes front-end loading difficult and the entire device occupies a large space. Patent publication number CN104670937A discloses an automatic laminating machine and automatic laminating method that can take a stack of silicon steel sheets with adhesion, extract, separate, position, and stack them, and stack them into a transformer core that meets high precision and high quality. However, the processing efficiency is low, and the processing efficiency is low, and it cannot meet the requirements of core lamination assembly for various models. Summary of the Invention

[0005] In view of the above problems, the present invention provides the following technical solutions:

[0006] A method for integrally grabbing, positioning, stacking and laminating single-stage wide sheet materials of transformer cores is provided, which is used to produce a preset number of cores at a time, wherein the preset number is more than one core, and comprises the following steps:

[0007] S1: Statistically calculate the quantity of sheet materials of each sheet width and sheet type required for a preset number of iron cores.

[0008] S2: According to the types of sheet widths of the required sheet materials, cut the large coils of silicon steel into silicon steel strip materials of corresponding widths.

[0009] S3: Cut each width of silicon steel strip material into corresponding sheet types. The sheet materials obtained after cutting are placed in trays. Each tray only stores sheet materials of the same sheet width and the same sheet type. The tray is equipped with positioning pins for positioning and fixing the sheet materials. On the tray, every time a certain quantity of sheet materials is placed, a partition is placed to separate them.

[0010] S4: Complete the lamination work on the lamination table. The lamination table includes a buffer area, a lamination area, and a manipulator. The trays containing sheet materials are placed in the buffer area. The lamination area has multiple lamination stations. Each lamination station is equipped with positioning pins for positioning and fixing the sheet materials. Each lamination station is used for laminating one sheet type of an iron core. Use the manipulator to pick up one level of sheet materials from the tray at a time and place them in the lamination station for lamination work. After each lamination station completes lamination, an iron core single column is formed.

[0011] S5: Transfer the iron core single column to the subsequent process to complete the assembly of the iron core.

[0012] Preferably, the iron core is a "day" - shaped iron core, which consists of three sheet types: side columns, yoke columns, and middle columns. In step S3, during the process of cutting the silicon steel strip material into corresponding sheet types, the side columns and yoke columns are combined for cutting, and the middle columns are cut separately.

[0013] Preferably, in step S4, the way for the manipulator to pick up one level of sheet materials from the tray at a time is the way of combining a suction cup and a gripper.

[0014] Preferably, the way for the manipulator to place the sheet material on the lamination station is as follows: The manipulator moves to a position 2 cm above the lamination station, uses the positioning pins of the lamination station for positioning, releases the suction cup and the gripper, and the sheet material completes stacking by free - falling.

[0015] Preferably, in step S4, the lamination sequence of the manipulator is as follows: First, laminate the sheet materials of the same sheet width of different iron cores, and then laminate the sheet materials of the next sheet width of different iron cores until all the lamination stations in the lamination area complete lamination. Beneficial effects:

[0016] 1. When the silicon steel sheet strip materials are horizontally sheared, the sheet materials of the same sheet width of multiple iron cores of the same type are uniformly punched and sheared, and each level is automatically separated by a partition; when laminating the iron core, a manipulator is used, and the single columns (side columns, yoke columns, and middle columns) are stacked by the method of grasping the whole level at a time. Then, the work of inserting the upper and lower yokes of the iron core is carried out in the subsequent general assembly process. The working efficiency of the horizontal shearing of the iron core sheet materials and the iron core lamination is respectively improved.

[0017] 2. The robot grabs the core of the same width in a single stage and moves it to the designated position in the stacking area. It accurately positions it to the designated height using the positioning pins. The grippers are then pulled out and the sheets automatically fall down to complete the stacking. The positioning method is simple and efficient.

[0018] 3. This invention, based on the traditional core shearing and stacking method, combines the unique characteristics of our product process. Multiple core sheets are uniformly cut, increasing cross-cutting production efficiency by approximately 20%. The resulting cut sheets are separated by partitions at each level, and the robot grabs the sheet from each level for stacking. This increases core stacking efficiency by 3-4 times. The use of partitions allows the robot to easily determine the number of sheets to be grabbed at each time, resulting in a simple implementation and excellent results. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] FIG1 is a top view of the core in the embodiment;

[0020] FIG2 is a cross-sectional view of a side column in an embodiment;

[0021] FIG3 shows the sheet type constituting the core in the embodiment;

[0022] FIG4 is a tray for placing 140 mm wide sheets in an embodiment;

[0023] FIG5 is a shear diagram of the side column and yoke column combination in the embodiment;

[0024] FIG6 is a shear diagram of a center column alone in an embodiment;

[0025] FIG7 is a structural diagram of the lamination table in the embodiment. DETAILED DESCRIPTION

[0026] In order to make the purposes, features, and advantages of the present invention more obvious and easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0027] A method for integrally grabbing, positioning, stacking, and laminating single-stage wide sheet materials of a transformer core is provided, which is used to produce a preset number of cores at a time. The preset number is one or more, and in this embodiment, four cores are produced each time, comprising the following steps:

[0028] S1: Count the number of sheets of various widths and types required for the four cores;

[0029] In this embodiment, the structure of each core is shown in Figures 1-3, which is a "sun"-shaped core. There are three types of sheets: side columns, yoke columns, and center columns. Each sheet type has multiple sheet widths. The side columns are installed on the left and right sides of each core, the yoke columns are installed on the upper and lower sides, and the center column is installed in the middle. Each sheet type is composed of six sheet widths of 260mm, 240mm, 220mm, 200mm, 170mm, and 140mm. Taking the side columns as an example, each core includes two side columns. In each side column, there are two levels of 140mm wide sheets, as shown in Figure 2. Therefore, each core has 4 levels of 140mm side columns. From this, it can be calculated that 4 cores require a total of 16 levels of 140mm side column sheets. By analogy, the number of sheets of each sheet width and sheet type can be calculated, as shown in Table 1.

[0030] Table 1 Statistics of sheet quantity for each sheet width and sheet type

[0031] S2: Cut the silicon steel coil into silicon steel strips of corresponding width according to the required sheet width;

[0032] In this embodiment, the silicon steel strips are cut into widths of 260 mm, 240 mm, 220 mm, 200 mm, 170 mm, and 140 mm, respectively.

[0033] S3: Cut each width of silicon steel strip into corresponding sheet shapes. The resulting sheets are placed on trays. Each tray only holds sheets of the same width and shape. The trays are equipped with positioning pins to position and secure the sheets. A partition is placed on the tray for each level of sheets. As shown in Figure 4, a tray for 140mm wide, side-column sheets is used. A partition is placed for each level of sheets (40 sheets per level, 140mm wide, side-column sheets).

[0034] Specifically, as shown in Figures 5 and 6, in the process of shearing the silicon steel strip into corresponding sheets, the side columns and yoke columns are sheared in combination, and the middle column is sheared alone.

[0035] S4: The stacking work is completed on the stacking table, which includes a buffer area, a stacking area, and a robot. The tray with the sheet material is placed in the buffer area. The stacking area has multiple stacking stations. Each stacking station is provided with a positioning pin for positioning and fixing the sheet material. Each stacking station is used to stack one type of sheet for an iron core. The robot is used to take one level of sheet material from the tray at a time and put it into the stacking station for stacking. After each stacking station completes stacking, a single column of the iron core is formed.

[0036] Specifically, the robot grabs one level of sheet material from the tray at a time using a suction cup and a gripper.

[0037] Specifically, the robot places the sheet material on the stacking station in the following way: the robot moves to a position 2 cm above the stacking station, uses the positioning pins of the stacking station for positioning, releases the suction cup and the claws, and the sheet material is stacked by free fall.

[0038] Specifically, the order of lamination by the robot is: first lamination of sheets of the same width for different cores, then lamination of sheets of the next width for different cores, until lamination is completed at each lamination station in the lamination area.

[0039] As shown in Figure 7, this is the stacking table in this embodiment. The robot stacks the 140mm wide sheets of 4 products in turn. After completion, it stacks the 170mm, 200mm, 220mm, 240mm, 260mm, 240mm, 220mm, 170mm, and 140mm wide sheets in turn.

[0040] S5: The core single column is transferred to the subsequent process to complete the assembly of the core. The subsequent process belongs to the existing technology and will not be described here.

[0041] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications should also be regarded as within the scope of protection of the present invention.

Claims

1. A method for integrally grasping, positioning and stacking single-stage wide sheet materials of a transformer core, which is used for producing cores of a preset number at one time, and the preset number is more than one, and is characterized in that Including the following steps: S1: Count the quantity of sheet materials with different widths and shapes required for a preset number of iron cores. S2: Cut the large silicon steel coil into silicon steel strips with corresponding widths according to the types of widths of the required sheet materials. S3: Cut each width of silicon steel strip into corresponding shapes. The sheet materials obtained after cutting are placed in trays. Each tray only stores sheet materials with the same width and the same shape. The tray is equipped with positioning pins for positioning and fixing the sheet materials. On the tray, every time a certain quantity of sheet materials is placed, a partition is placed to separate them. S4: Complete the lamination work on the lamination table. The lamination table includes a buffer area, a lamination area, and a manipulator. The tray containing the sheet materials is placed in the buffer area. The lamination area has multiple lamination stations. Each lamination station is equipped with positioning pins for positioning and fixing the sheet materials. Each lamination station is used for laminating one type of sheet shape of an iron core. Use the manipulator to take one level of sheet materials from the tray at a time and place them in the lamination station for lamination work. After each lamination station completes lamination, an iron core single column is formed. S5: Transfer the iron core single column to the subsequent process to complete the assembly of the iron core.

2. A method for overall grasping, positioning, stacking and laminating of single-stage wide sheet materials of a transformer core according to claim 1, characterized in that The iron core is a "day"-shaped iron core, composed of three sheet shapes: side columns, yoke columns, and middle columns. In step S3, during the process of cutting the silicon steel strip into the corresponding sheet shape, the side column and yoke column are combined for cutting, and the middle column is cut separately.

3. A method for integrally grasping, positioning, stacking and laminating a single-stage wide sheet material of a transformer core according to claim 1, characterized in that In step S4, the way the manipulator takes one level of sheet materials from the tray at a time is by using a suction cup plus a gripper.

4. A method for integrally grasping, positioning, stacking and laminating single-stage wide sheet materials of a transformer core according to claim 3, characterized in that The way the manipulator places the sheet materials on the lamination station is: The manipulator moves to a position 2 cm above the lamination station, uses the positioning pins of the lamination station for positioning, releases the suction cup and the gripper, and the sheet materials complete stacking by free fall.

5. A method for integrally grasping, positioning, stacking and laminating single-stage wide sheet materials of a transformer core according to claim 1, characterized in that In step S4, the lamination sequence of the manipulator is: First, laminate the sheet materials with the same width of different iron cores, and then laminate the sheet materials with the next width of different iron cores until all the lamination stations in the lamination area have completed lamination.

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