AND METHOD

Technical Field

The invention relates to a machine and method for producing magnetic cores from thin film tapes of material by winding.

Prior Art

In most applications in the current technique, the tape winding technique is used but the mechanical tension is kept arbitrary during core winding. Cores wound with arbitrary mechanical tension achieve standard electrical and magnetic properties. In addition, in many commercially available versions, the source and target shafts are controlled by the motor drive, resulting in a mechanical tension shift of around 5% for different cores. After this shift, the energy efficiency of the produced core changes. In addition, not all cores in the same production series have standardized electrical and magnetic properties.

Application CN211529784U relates to a magnetic core winding machine. A schematic view of the machine is shown in Figure 1. The application relates to a film release disk on which the amorphous film is placed and a winding disk on which the material transferred from this disk is wound. The application also mentions that the winding tightness of the magnetic core will affect the performance of the magnetic core, and to solve this problem, a tensioning device positioned between the unwinding disk and the winding disk to control the tension of the wound film and various tension sensors to adjust the level of tension are mentioned. The tension of the material is adjusted with a tension sensor between the source and target shafts and the winding tension of the tape is automatically kept under control. However, in this device, there is no mention of a holder for winding the tape and a mechanism to stabilize the tension of the tape during winding. There is also no mention of a welding device that allows the core winding to be welded together and a mechanism that allows this welding device to move up and down to weld.

Another system (Gunes, T. (2019) "Novel method for construction of high performance nanocrystalline FeCuNbSiB toroidal core") is similar to the subject of the invention but differs from the invention in terms of working dynamics. For example, the working principle of the system in question envisages that the source and target rollers rotate at different speeds along the core winding. However, a large number of controls are required to control this situation. Furthermore, this winding method envisages a process that gradually increases the tape tension until the core winding is completed. This prevents a homogeneous mechanical tension and can lead to tape rupture during production.

As a result, due to the above-mentioned problems and the inadequacy of the existing solutions, it was deemed necessary to make an improvement in the relevant technical field.

Purpose of the Invention

The purpose of the invention is to produce a magnetic core from a thin tape of material by winding. This type of machine is used to produce magnetic cores in toroidal, oval or planar shapes by subjecting amorphous and nanocrystalline tapes to certain mechanical tensions. The machine works in a similar way to the tape-winding method. However, a mechanical tension is created by utilizing angular velocity differences between the target and source shafts. It has been observed that the performance of magnetic cores wound with this mechanical tension is improved.

With the invention, the target holder is controlled by an electromagnet and after the winding has completed one turn, the tape is fixed at the specified mechanical tension with a spot-welding device. Then, after the winding is completed and the core is produced, the core is ensured to be monolithic with the spot-welding machine and the electromagnet is deactivated and the core is released. Not only the mechanical tension part of the process has been successfully demonstrated, but also the processes required to complete the winding of the core at the specified mechanical tension.

The structural and characteristic features and all advantages of the invention will be more clearly understood by means of the following figures and the detailed description with reference to these figures.

Description of Figures

Figure 1 is a schematic view of a system in the current technique.

Figure 2 is a view of the inventive magnetic core production device.

The drawings are not necessarily to scale and may omit details that are not necessary to understand the present invention. Description of Part References

1. Feed motor

2. Winding motor

3. Linear drive mechanism

4. Rectilinear drive mechanism

5. Tension sensor

6. Routing pulley

7. Thickness sensor

8. Worm gear-1

9. Worm gear-2

10. Laser absorber

11. Guide roller-1

12. Welding machine

13. Variable diameter magnetic holder

14. Motor controller

15. Power supply

16. Variable diameter magnetic feed holder

17. Guide roller-2

Detailed Description of the Invention

In this detailed description, the preferred embodiments of the invention are described solely for the purpose of a better understanding of the subject matter and without limiting effect.

The inventive magnetic core production device with variable mechanical tension is a device capable of winding magnetic toroid-shaped cores under tension. The material to be used for this purpose is an alloy of different metals in the form of a thin film. When tension is applied to the material in question, the electromagnetic properties of the material will improve. Accordingly, the developed magnetic properties will be maintained by creating toroid cores that will be wound under tension and fixed in this position. The magnetic core manufacturing device includes a feed motor and winding motor (1 , 2), two holders (13, 16), a welding machine (12) and a positioning mechanism for it, two worm gears (8, 9), a laser cutter, a routing pulley (6), a tension sensor (5), a laser absorber (10), guide rollers (11 , 17), a power supply (15) and a motor controller (14). These components are fixed together on a board in their relative positions.

In the working principle of the invention, a roll of non-tensioned material consisting of many turns is first placed on the holder (16), which is driven along the worm gear-2 (9). The material is separated from the roll and fed to the guide rollers (11 , 17) on the tension sensor (5), then to the routing pulley (6) and finally to the variable diameter magnetic holder (13). The magnetic coil in the holder (13) is activated to fix the material on the magnetic holder (13). The winding motor (2) rotates until the material forms a ring. The welding machine (12) is then moved downwards by the linear drive mechanism (3), the positioning mechanism holds the material stationary and the welding machine (12) welds. After the process, the welding machine (12) is moved up again. At this stage, the diameter of the variable diameter magnetic holders (13, 16) increases to prevent the roll and ring from rotating and losing tension relative to the holders. To help with this, the surfaces of the holders (13, 16) are formed from a rubber-like material with a high coefficient of friction compared to the metal material. To stop the feed winding from rotating, the feed motor (1) enters brake mode with the help of the controller (14). Worm gears (8, 9) are fitted to both outputs of the motors (1 , 2) to further reduce the possibility of rotation as any small rotation can mean a change in tension. The worm gear sets (8, 9) can only be driven by the motors (1 , 2) and not vice versa. In the next step, the winding motor (2) rotates several steps, creating tension on the material.

After the tension is achieved, the motors (1 , 2) start to rotate at exactly the same time and speed. This will ensure that the tension is kept constant while the material is wound. Since locking the rotor with the rotating magnetic field of the stator is a design feature of stepper motors and thanks to the worm gears (8, 9), it is ensured that the tension will not change due to small changes in torque and speed. A tension sensor (5) is installed between the guide rollers (11 , 17) to monitor the tension in the material. When the desired number of turns or thickness (continuously measured by the thickness sensor (7)) is reached, both motors (1 , 2) stop and enter brake mode. At this point, the welding machine (12) is moved downwards, and the winding is fixed by welding. The laser cutter, which is placed tangentially to the coil, can then be moved by the rectilinear motion mechanism (4) to cut the material. At this point, if necessary, the winding motor (2) can move back a few steps to expose the material and ensure a better cut. As laser beams can be dangerous, a laser absorber (10) is placed opposite the cutter to prevent the laser beams from reflecting. At this stage, the second holder (13) (on the winding side) reduces its diameter to reduce the tension and the core can be removed. After the material has been cut, the routing pulley (6) guides the material into the magnetic holder (13). After that, the process can be repeated. The whole process is automatic and can be adjusted with the help of the controller (14).