JPS6059731B2 - High voltage transformer manufacturing equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to high voltage transformer manufacturing equipment for manufacturing high voltage transformers such as flyback transformers by injecting and curing insulating resin.

Among high voltage transformers, for example, flyback transformer 1 is
Case 1a made of synthetic resin as shown in Figure 1
A schematic structure in which the primary coil (lb), secondary coil (lc), and other necessary parts (le not shown) are assembled, wiring and other necessary processing is performed, and synthetic resin (ld) is injected into this and hardened and fixed. Here, the synthetic resin is used to firmly bond these parts mechanically and to provide necessary electrical properties such as insulation, voltage resistance, and other properties. However, in order to fully demonstrate the performance of the resin and provide the necessary characteristics, it is necessary to use synthetic resins.
It is necessary to fill and impregnate the wire into the gaps between the wires wound into coils without air bubbles, and the quality of this treatment determines the quality of the product, and this treatment method also determines the manufacturing cost. This was a major contributing factor. Therefore, as previously disclosed in Japanese Patent Application Laid-open No. 53-423D, the main agent,
A continuous system is equipped with a defoaming means for storing each curing agent independently and defoaming in vacuum and air, and a mixing means connected to the defoaming means in a sealed pipe to mix the base agent and the curing agent at a predetermined mixing ratio. a vacuum injection tank configured to be maintained in a vacuum state and inject the synthetic resin mixed and defoamed by the above device into products such as high-voltage transformers; and a vacuum injection tank adjacent to the vacuum injection tank. It is equipped with a defoaming tank for defoaming the synthetic resin injected into the product by vacuuming it, and a conveying device for vertically transporting the product injected with the synthetic resin, as well as a predetermined transport system. A curing furnace that heats according to a temperature profile to cure the synthetic resin injected into the product; and a conveying device that transports the product injected with the synthetic resin from the defoaming tank to the curing furnace and is covered to isolate it from outside air. There is a manufacturing facility for high voltage transformers equipped with

However, this high-voltage transformer manufacturing equipment is equipped with a transfer type tank equipped with a vacuum injection tank and a degassing tank, as well as a continuous hardening furnace configured to heat to a predetermined temperature profile along the conveyance path. Therefore, although it is suitable for mass production, it is not suitable for small quantity production and has the drawback of being extremely expensive. The purpose of the present invention is to eliminate the above-mentioned conventional drawbacks, and to enable injection and curing of synthetic resin into a high-voltage transformer in a batch-type and near-continuous type so as to be suitable for small-scale production. To provide a manufacturing facility for a high voltage transformer that is sealed, safe from the toxicity of resin, and allows easy high quality control.

That is, the present invention provides a defoaming means for storing a base agent and a curing agent separately and degassing them under vacuum, and a defoaming means that is sealed with the defoaming means. A device that is connected to piping and is equipped with a mixing means that mixes the main agent and curing agent at a predetermined mixing ratio and continuously mixes and defoams, and a first conveyor device that is equipped with a high-pressure transformer and that conveys intermittently. High pressure is installed internally and is transported by this first transport device! A vacuum injection tank for injecting the synthetic resin defoamed by the above device into the transformer in a vacuum state, and a second conveying device for vertically conveying the high voltage transformer injected with the above synthetic resin are installed inside the transformer, and the transformer is made into a block. A temperature regulator that is equipped with a thermometer that measures the temperature within each block and is configured such that the temperature measured by the thermometer can be set to an arbitrary value in correspondence with each block, and a temperature regulator that is configured to set the temperature measured by the thermometer to an arbitrary value in correspondence with each block; Provide at least three sets of timers connected in series to operate the
a curing furnace configured to operate heaters in each block in the three sets, and heat each block at a predetermined temperature profile over time to cure the synthetic resin injected into the high-pressure transformer; A third transport device is installed to transport the high-voltage transformer injected with the synthetic resin from the vacuum injection tank to the curing furnace, and is covered to isolate it from the outside air, from vacuum injection of the synthetic resin to the high-voltage transformer to curing. This method is characterized by being able to perform partial batch processing.

The present invention will be explained below based on embodiments shown in the drawings.

FIG. 2 is a perspective view of the entire schematic configuration of an embodiment of the high-voltage transformer manufacturing equipment of the present invention, FIG. 3 is a sectional view showing the vacuum injection tank shown in FIG. 2, and FIG. 4 is the same as that shown in FIG. FIG. 5 is a schematic configuration diagram showing a temperature control device for a hardening furnace shown in FIG. 5, and FIG. 5 is a sectional view showing each block forming the hardening furnace.

That is, 2 is an annealing furnace for drying and annealing the coil of the flyback transformer 1. Reference numeral 4 designates a workbench for repacking the flyback transformers 1 into several alignment jigs 3 arranged at equal intervals on the circumference.

5 is a heating furnace for improving the wetting properties of the coil and the injection properties.

6 is a dedicated tank 1 for each main agent (epoxy compound, silicone resin, etc.) and curing agent (acid anhydride, chloroplatinic acid, etc.)
Vacuum defoaming the resins 3a, 13b and 14a, 14b,
This automatic resin metering, mixing and discharging device is configured to then pressurize with dehumidified air and discharge a fixed amount of mixed resin from a nozzle while continuously mixing and stirring at a prescribed blending ratio.

That is, the main agent tank 13a1, the main agent reserve tank 13b1, the curing agent tank 14a1, and the curing agent reserve tank are undiluted solution cans (not shown).
It is formed of an airtight container provided with an inlet connected to the pump, and is connected to vacuum pumps 9a and 9b and pressure pumps 21a and 21b via switching valves. Also, main agent tank 1
3a, 13b1 Hardening agent tanks 14a, 14b include an agitator for stirring, a motor for rotationally driving this agitator, a band heater that heats the resin to make it low in viscosity, and a band heater that measures the temperature of the resin and turns the band heater 0N and 0FF. A thermostatic thermocouple is installed to control and maintain the temperature at a predetermined temperature. The main agent pressure feeding pipe and the hardening agent pressure feeding pipe connected to the main agent tank 13a1, the main agent reserve tank 13b1, the hardener tank 14a1, and the hardener reserve tank 14b via switching valves (not shown) are connected to the main agent measuring cylinder 15a.
, 15b check valves, curing agent metering cylinders 16a, 16b
is connected to the check valve. These check valves are integrally made at the bottom of each metering cylinder 15a, 15b and 16a, 16b, and suck the base agent and curing agent into each metering cylinder 1.
5a, 15b1 and 16a, 16b. Also, measuring cylinders 15a, 15b and 16a
, 16b to the pressure feed pipes to the mixers 17a1 and 17b. Base agent measuring cylinder 15a
, 15b and the curing agent metering cylinders 16a, 16b have an area ratio equal to the mixing ratio and are slidably fitted with respective metering pistons that move with the same stroke. mixer 17a,
Each of the pipes 17b is connected to a check valve and a pressure feed pipe, and connects the mixed liquid pipes 20a and 20b to the outlet side. The intermediate portion forms a sealed cylinder, and within this sealed cylinder, a stirring blade is rotatably supported by a bearing portion sealed with an oil seal or the like, and the stirring blade is configured to be rotationally driven by an air motor or the like. Also, check valves are provided at the inlets of the pipes from the metering cylinders 15a, 15b1 and 16a, 16b. The injection nozzles 8a, 8b are connected to the ends of the liquid mixture pipes 20a, 20b, and are configured to be opened and closed by a valve spool connected to a piston rod of an air cylinder. Note that the bearing of the valve spool is also sealed with packing. In addition, scattering prevention covers are attached to the tips of the injection nozzles 8a and 8b. 21a, 21
b is a tank 13 dedicated to each main agent from each stock solution can (not shown).
a, 13b, the main agent to each curing agent dedicated tank 14a, 14b,
This is a pressure pump that replenishes hardening agent.

7a, 7b are each connected to a vacuum pump 9c, and 4 to 40
In a vacuum injection tank formed to create a vacuum atmosphere of T0rr, an alignment jig 3 in which flyback transformers 1 are arranged at equal intervals on the circumference is placed and rotated intermittently at equal angular intervals by a motor 24. A turntable 22 configured to do this is installed, a door 23 is provided for taking in and out these alignment jigs 3, and a ceiling 25 and the like are made of transparent resin so that the inside can be clearly observed. 11a to 11j, after the predetermined amount of alignment jigs 3 have been accommodated, the entire inside of the furnace is heated to 40°C for 3 hours as shown in Fig. 7 in the first step, and then heated to 80'C for 2 hours. The temperature profile is carried out from the second step B2 of heating to the third step B3 of heating to 120° C. for 2 hours to cure the synthetic resin injected into the flyback transformer 1 in a batch manner, and also to harden the synthetic resin in the conveying path. As shown in FIG.
e, 8f area is 80℃, 8h, 81 area is 120℃
By creating regions with different temperatures and passing through each region continuously from the inlet to the outlet for 1 ctf, it is also possible to continuously cure the synthetic resin injected into the flyback transformer with the above temperature profile. This curing furnace is configured such that the aligning jig 3 can be automatically introduced from the inlet by a pusher 26.

That is, the curing furnaces 11a to 11j are constructed by passing a conveyor 27 vertically through the center of a tunnel-type heating section, and the heating section is connected to a duct connected to an air conditioner that cleans and discharges gas accumulated inside. . Hardening furnace 11 each made into blocks
a to 11j are partitioned and sealed together with the alignment jig 3 equipped with the flyback transformer 1, leaving a space for passing through the conveyor 27, and when heated as shown in FIG. A cross-flow fan 29 connected to a motor 28 is used to circulate hot air from the ceiling to the flyback transformer 1 as shown by an arrow 1. These curing furnaces 11a to 11
At the entrance of j, there is a door (
(not shown) is provided. Furthermore, depending on the temperature conditions, air curtains are formed at both the inlets and outlets of the curing furnaces 11a to 11j. Constant temperature baths 11a to 11j for each block
, temperature regulators Kal~KalO, timers Tal~TalO, relays A1~A, O, and electric current are connected in series, temperature regulators Kbl~KblO, timers Tbl~TOIO, and relays B1~ BLO and the power supply E
7 connected in series to 1, temperature regulators Kc, ~Kcl
O, timer TCl to TClO, and relay C1 to ClO
and are connected in series to the power supply E1, and the timers Tal to TalO are equipped with a batch type start switch R.
is connected via power supply E2, and switch S1 for continuous type
are connected to both ends of the timer Tal~TalO. The relays A1 to AlO9Bl to BlO9Cl to ClO are connected between the power source EO and each of the heaters H1 to HlO.
Switch a1'ValO9blゞBl operated by
O9ClXClO are connected in parallel. Furthermore, temperature regulators Kal~Ka, O, Kbl~Kb, O, KCl~KC
The outputs of the thermometers F1 to FlO are input to lO.
However, the temperature regulators Kal to KalO were adjusted to 40°C,
The temperature regulators Kbl to KblO are adjusted to 80°C, and the temperature regulators KCl to KClO are adjusted to 120°C. Also, timer Tal~Tal. is 3 hours, timer Tbl~Tb
IO is set to 2 hours, and timers TCl to TClO are set to 2 hours. Once the flyback transformer 1 is housed in the curing furnaces 11a to 11j in this way, when the conveyor 27 is stopped and the batch type start switch R is pressed, the timer Tal is activated for 3 hours and the temperature is measured. Vessel F1~
When the temperature detected from FlO becomes 40°C or lower, temperature regulators Kal to KalO turn ON, relays A1 to AlO operate, switches a1 to AlO close, and heaters H1 to H
A power source is supplied to lO, and all thermostatic chambers 11a to 11j
is maintained at 40℃±5℃, and the timer Tal~TalO
At the same time as the timer turns off after 3 hours, the timer Thl~
When TblO is activated for 2 hours and the temperature detected from thermometers F1 to FlO becomes 80°C or lower, temperature regulator Kbl
~KblO is set to ON, relays B1 to BIO are activated, switches Kg to BIO are closed, and power supply E is applied to heaters H1 to HIO. is supplied, all thermostatic chambers 11a to 11j are maintained at 80°C±5°C, and timers Tbl to TOIO are turned off after 2 hours, and at the same time timers TCl to TCl are turned off.
. is activated for 2 hours and when the temperature detected by thermometers F1 to FlO becomes 120°C or lower, temperature regulators KCl to K
ClO becomes ON, relays C1 to ClO operate, and switches C1 to Cl. is closed, and power supply E is applied to heaters H1 to HIO.
is supplied, and all thermostats 11a to 11j are kept at 120°C.
Maintained at ±5°C. Next, in the case of continuous type, constant temperature bath 11
a to 11c. 4 compatible temperature regulators Kal to Ka3
Temperature regulator Ka adjusted to 0°C and compatible with constant temperature bath 11d
4 to 60°C, temperature regulators Ka5 and Ka6 corresponding to thermostatic chambers 11e and 11f to 80°C, and thermostatic chamber 1.
Adjust the temperature regulator Ka7 corresponding to 1g to 100℃,
Temperature regulator Ka7 compatible with constant temperature j baths 11k to 111
Adjust Ka, to 120°C and close switches S1 to S9.
When the conveyor 27 is in operation, the thermostatic chambers 11a~
For 11c, temperature regulator Kal to Ka3, relay A
1 to A3, switches a1 to C3 operate, and the constant temperature chamber 111
For e and 11f, temperature regulators Ka5 and Ka6, relays A5 and A6, and switches A5 and a6 operate, and thermostatic chamber 1
For 1h and 111, temperature regulators Ka8 and Ka9, relays A8 and A9, and switches A8 and a9 are activated, and the flyback transformer 1 mounted on the conveyor 27 is cured at the temperature profile shown in FIG. 6 while being conveyed. 1C
It will be discharged after a period of time.

The exposed portions of these vacuum injection tanks 7a, 7b1 and curing furnaces 11a to 11j are surrounded by a blocking dome or a booth 30, and connected to a duct of an air conditioner (exhaust device) to be cleaned. In particular, in the vacuum injection tanks 7a and 7b, the operations of supplying and removing the alignment jig 3 to and from the tanks are carried out using vinyl gloves 32 attached to a transparent resin face 31 as shown in FIG. Reference numeral 10 denotes an input conveyor that sequentially conveys the alignment jig 3 from before the vacuum injection tanks 7a, 7b to the entrances of the curing furnaces 11a to 11j.

A door 33 that can be opened and closed is provided at the right end of the feeding conveyor 10 as shown in FIG. There is. 12 is the completed flyback transformer 1
This is a finished product conveyor that guides the alignment jig 3 on which the curing furnaces 11a to 11j are placed to the work table 4 from the exits of the curing furnaces 11a to 11j.

34 is a control device that centrally controls these devices, and is designed to monitor the operation of each device on a graphic panel, and also inputs signals from a detector (not shown) installed at the location of the pusher 26. The number of alignment jigs 3 accommodated in the curing furnaces 11a to 11j can be counted and displayed.

With the above configuration, each step is performed as follows.

That is, the flyback transformer 1 is transported and floated in the direction of the arrow. The flyback transformer 1 carried from the assembly line 35 in a box or the like is put into an annealing furnace 2 set at a constant temperature, where it is annealed and dried for a specified time. After that, a regular number of flyback transformers 1 are lined up on each alignment jig 3, placed on the charging conveyor 10 through the door 33, and placed in a vacuum injection tank using a vinyl glove 32 attached to a transparent resin face 31. 7a, 7
The liquid is supplied onto the turntable 22 in b, and the vacuum door 23 made of transparent resin such as acrylic is closed. After turning the foot switch (not shown) to 0N, when the specified degree of vacuum is automatically reached, nozzles 8a and 8a, which are provided on plates made of transparent resin or the like stretched over the tops of vacuum injection tanks 7a and 7b, are activated.
From 8b, the synthetic resin mixed by the resin automatic metering, mixing and discharging device 6 is injected into the flyback transformer 1.
That is, since the main material and curing agent usually contain a large amount of air bubbles, a main tank and a spare tank are provided respectively, and while the new material is being injected, the new material is vacuum degassed. Since the reserve tank is provided in this manner, the main agent and curing agent are completely vacuum degassed over a long period of time. The main ingredient is 3.5
~ 5 hours, hardening agent completely over 2 to 4 hours (main agent is 2 to 4 hours)
．． 5T0rr1 curing agent is about 1.8T0rr) defoaming,
308 from injection nozzles 8a and 8b? Synthesis is carried out by injecting in one operation (cycle) into the flyback transformer 1 placed in the vacuum injection tanks 7a and 7b in a vacuum atmosphere of 4 to 4.0 T'0rr at a slow rate over a period of . The resin can be injected very smoothly without overflowing or scattering. In this manner, after the quantitative injection is completed, the turntable 22 rotates intermittently to inject the synthetic resin into the next flyback transformer 1 in a vacuum atmosphere, and degassing is also performed. Thereafter, this rotation ● injection continues until all flyback transformers 1 are injected.

When the injection is completed, vacuum is maintained for a specified period of time, bubbles are degassed, and the container is opened to the atmosphere. Here, the operator again uses the vinyl gloves 32 attached to the transparent resin face 31 to open the door 23 made of transparent resin, etc., and pulls out the alignment jig 3 to the input conveyor 10 in front and places it thereon. The alignment jig 3 placed on the input conveyor 10 is automatically placed in the curing furnace 1.
It is thrown into the inside from the entrance of 1a to 11j. When a predetermined number of alignment jigs 3 are put into the curing furnaces 11a to 11j, the batch type start switch R is pressed and the first step B1, the second step B2, and the third step are started as shown in FIG. In step B3, the flyback transformer is hardened using a batch temperature profile. After curing according to this temperature profile, the alignment jig 3 can be taken out by sawing from the exit side, and the alignment jig 3 can be placed on the finished product conveyor 12.
Once completed, the flyback transformer 1 is taken out and transported to the assembly line 35 again. If you want to further increase the production volume, adjust the temperature regulators Kal to KalO to their respective predetermined temperatures and close the switches S1 to S9.
As shown in the figure, by creating different temperature ranges in the curing furnace and running the alignment jig 3 at a constant speed, continuous curing can be achieved. Therefore, by switching according to the production volume, injection hardening can be performed in accordance with the production volume. Furthermore, if it is necessary to preheat the flyback transformer 1 on the injection side, the subsequent work can be carried out efficiently by putting the alignment jig 3 into the heat insulating furnace 5 while it is still set there.

Although the device shown in Figure 2 is intended for one type of resin,
By adding one automatic resin metering, mixing and discharging device 6 to the same area and replacing the nozzle, it becomes possible to inject and harden two types of resin, which also leads to a reduction in equipment costs.

As described above, the present invention has the remarkable effect of providing a safe and inexpensive high-voltage transformer manufacturing facility that can be switched in response to fluctuations in production volume.

[Brief Description of the Drawings] Fig. 1 is a cross-sectional view showing a flyback transformer according to the present invention, Fig. 2 is an overall perspective view showing an embodiment of the high-voltage transformer manufacturing equipment of the present invention, and Fig. 3 is a cross-sectional view showing a flyback transformer according to the present invention. is a sectional view showing the vacuum injection tank shown in Fig. 2, Fig. 4 is a schematic configuration diagram showing the temperature control device of the curing furnace shown in Fig. 2, and Fig. 5 shows each block forming the curing furnace. A sectional view, FIG. 6 is a diagram showing a continuous type temperature profile in a hardening furnace, and FIG. 7 is a diagram showing a batch type temperature profile in a hardening furnace.

Claims (1)

[Claims] 1 Equipped with a defoaming means for storing the base agent and the curing agent separately and degassing them under vacuum, and a mixing means connected to the degassing means in a sealed pipe to mix the base agent and the curing agent at a predetermined mixing ratio. A first conveying device equipped with a device for mixing and defoaming and a high-voltage transformer and conveying intermittently is installed, and the high-voltage transformer conveyed by this first conveying device is in a vacuum state. A vacuum injection tank for injecting the degassed synthetic resin, and a second conveying device for vertically conveying the synthetic resin injected into the high-voltage transformer are installed, and the system is divided into blocks and the temperature inside each block is measured. In addition, a temperature regulator configured so that the temperature measured by the thermometer can be set to an arbitrary value corresponding to each block, and a timer that operates at a predetermined time are connected in series. At least three sets are provided, and the heaters in each block are operated by the three sets, and each block is heated by changing a predetermined temperature profile over time, and the high voltage transformer is heated. A curing furnace for curing the injected synthetic resin, and a third transport device that transports the high-voltage transformer injected with the synthetic resin from the vacuum injection tank to the curing furnace and are covered to isolate it from outside air are provided. A high-voltage transformer manufacturing facility that is capable of partial batch processing from vacuum injection of synthetic resin to curing.