Iron core roll forming equipment and forming process

Abstract

The invention provides iron core roll forming equipment and a forming process, and relates to the technical field of transformer manufacturing. An operation vertical plate is vertically arranged at the upper end of the base; the controller and the laser welding machine are fixedly hung on the operation vertical plate; one end of the operation vertical plate is rotationally provided with a material frame for storing iron sheets which are not slotted, and the other end of the operation vertical plate is provided with a winding roller for winding the slotted iron sheets. And a stamping mechanism and a cutting mechanism are arranged on the operation vertical plate between the material frame and the winding roller. Through mechanical linkage of the stamping mechanism, the winding driving mechanism, the correcting mechanism and the spot welding mechanism and cooperation of electric control signals, automation of the whole process of grooving, winding, thickness monitoring, cutting and welding of the iron core roll is achieved. A stamping-cutting-winding integrated machining mode is adopted, and the problems that in the prior art, in the process that too many iron sheet coiled materials are uniformly and completely slotted and then wound in advance, the occupied space is too large, and the coiled materials are prone to being uneasy to convey, bent and damaged due to slotting can be solved.

Description

Technical Field

[0001] The present invention relates to the technical field of transformer manufacturing, and particularly relates to an iron core coiling and forming device and a forming process. Background Art

[0002] As a core component of electromagnetic equipment, the forming process efficiency and quality of the iron core coil directly affect the product performance. The traditional manufacturing process usually adopts a step-by-step operation mode: first, a batch of iron sheets are slotted by an independent stamping device, and then the slotted iron sheets are transferred to the winding station for manual or semi-automatic winding. This process has significant defects: firstly, the pre-slotted iron sheets are prone to bending deformation or surface scratches during storage and transportation due to the slot structure, resulting in layer misalignment or loose fitting during winding; secondly, the step-by-step operation requires a large amount of space for temporarily storing semi-finished products, and the process connection depends on manual intervention, with low efficiency and difficult to guarantee consistency. In addition, the traditional winding equipment lacks a dynamic deviation correction mechanism, and the edges of the iron sheets are prone to offset during continuous winding, resulting in the accumulation of interlayer gaps in the iron core coil and the decrease of density with the increase of thickness, affecting the magnetic circuit performance.

[0003] In the fracture welding link, the existing technologies mostly rely on manual positioning or fixed welding torches, with problems such as inaccurate welding timing and large positioning deviation, resulting in insufficient fracture joint strength and easy cracking during subsequent processing. At the same time, the drive systems of the stamping and winding equipment are often independently controlled, making it difficult to achieve strict synchronization of the slotting spacing and winding pitch, and prone to defects such as iron sheet stretching deformation or slot misalignment due to speed differences. Summary of the Invention

[0004] The present invention relates to an iron core coiling and forming device and a forming process, which realize the full-process automation of "winding - monitoring - cutting - welding" through the precise coordination of mechanical linkage and electric control signals, and significantly improve the efficiency and consistency of iron core coil forming.

[0005] The present invention provides an iron core coiling and forming device and a forming process, which specifically include: a base; an operation vertical plate is vertically arranged at the upper end of the base; a controller and a laser welding machine are fixedly hung on the operation vertical plate; a material rack for storing unslotted iron sheets is rotatably arranged at one end of the operation vertical plate, and a winding roller for winding the slotted iron sheets is arranged at the other end of the operation vertical plate; a stamping mechanism and a cutting mechanism are arranged on the operation vertical plate between the material rack and the winding roller, the stamping mechanism is close to the material rack, and the cutting mechanism is close to the winding roller; the stamping mechanism is composed of a stamping frame and a stamping table, and the stamping frame is above the stamping table; the cutting mechanism is composed of a cutting frame and a cutting guide table, and the cutting frame is above the cutting guide table; a forming pressure column is vertically and horizontally fixedly arranged on the operation vertical plate directly above the winding roller, and a movable hole is vertically arranged on the operation vertical plate at the position where the winding roller is located, and the winding roller can move vertically in the movable hole; a straightening mechanism is vertically arranged on the forming pressure column, and a spot welding mechanism is arranged on the straightening mechanism and penetrates through the forming pressure column; the straightening mechanism is composed of a gantry-shaped structure formed by a counterweight cross bar and a straightening guide rod, which is used to ensure the neatness during the iron core coiling and forming process; the spot welding mechanism is composed of an adjusting screw, a spot welding frame, a scale and a welding contact seat, and the broken port is spot welded and fixed after a coil of iron core is wound and formed.

[0006] Optionally, two layers of pressing rods are vertically arranged on the operation vertical plate between the material rack and the stamping table, the unslotted iron sheets pass through between the two layers of pressing rods, and the upper pressing rod is misaligned and leans towards the material rack to press the material line of the unslotted iron sheets.

[0007] Optionally, the upper end of the stamping frame is a vertical stamping cylinder, and the piston rod of the stamping cylinder is fixedly connected downward with a stamping die head, and the stamping die head moves downward to slot the iron sheet passing below.

[0008] Optionally, a discharge hole vertically corresponding to the stamping die head is vertically opened in the stamping table, and the lower end of the stamping table at the discharge hole is an inclined cutting structure outward and downward.

[0009] Optionally, the middle part of the upper end of the cutting frame is a vertical cutting cylinder, and the end of the piston rod of the cutting cylinder is fixedly connected vertically downward with a cutter, and the cutter moves down to the cutting guide table to cut the slotted iron sheet passing by.

[0010] Optionally, the upper end surface of the stamping table, the upper end surface of the cutting guide table and the lower end of the forming pressure column are always on the same horizontal plane.

[0011] Optionally, a sleeve block is rotatably sleeved on the rotating shaft at one end of the roller close to the operation vertical plate. The sleeve block is vertically slidably clamped in the movable hole. A forming motor is fixedly arranged at one end of the sleeve block away from the roller to drive the roller to rotate. A suspension rod is vertically arranged at the upper end of the sleeve block. The upper end of the suspension rod vertically slides through the fixing plate. The fixing plate is fixedly connected to the operation vertical plate. A stop disc is arranged at the end of the suspension rod. A first spring is sleeved on the suspension rod between the stop disc and the fixing plate. The first spring provides an upward pulling force for the sleeve block all the time. The rotation angle of the forming motor driving the roller is consistent with the slotting spacing of the iron sheet. Each time the stamping cylinder stamps once, the forming motor winds one unit.

[0012] Optionally, annular alignment ring grooves are respectively formed on the roller surfaces at both ends of the roller. Correction guide rods are respectively and vertically slidably arranged at positions corresponding to the alignment ring grooves vertically at both ends of the forming pressure column. The lower ends of the correction guide rods are spherical structures, and the lower ends of the correction guide rods are always slidably placed in the corresponding alignment ring grooves. A counterweight cross bar is arranged between the upper ends of the two correction guide rods. The upper ends of the correction guide rods and the counterweight cross bar are vertically and rotatably connected through a rotating shaft. The slotted iron sheet is wound on the roller between the two alignment ring grooves. The correction guide rods are tangent to the edges of the wound iron sheet. As the wound iron sheet increases, the roller moves downward, the first spring is compressed, and the extrusion force between the iron sheet on the roller and the forming pressure column increases. The iron sheet at the bottom of the forming pressure column always maintains the same height to keep the winding stable.

[0013] Optionally, the middle part of the upper end of the counterweight cross bar is vertically and rotatably connected to the adjusting screw. The counterweight cross bar on one side of the adjusting screw is a vertically upward scale. The middle part of the gantry-shaped spot welding frame is rotationally and threadedly connected to the adjusting screw. The upper end of the scale vertically slides through the spot welding frame. The lower end of the scale is the scale zero point. The two ends of the spot welding frame vertically pass through the counterweight cross bar and pass through the forming pressure column below. A table groove is opened on one side of the lower end of the spot welding frame close to the cutting frame. A "T"-shaped welding contact seat is vertically slidably arranged in the table groove. Two symmetrical inserting rods are vertically arranged at the upper end of the welding contact seat. A second spring is sleeved on the inserting rods. The inserting rods vertically slide and are inserted into the top of the table groove. Limiting columns are symmetrically and vertically arranged on the left and right at a position close to the lower end of the table groove. The limiting columns are used to stop the welding contact seat to prevent the welding contact seat from moving downward and becoming dislocated. A pressure sensor is arranged at the bottom of the welding contact seat. A laser welding head inclined downward is arranged on one side of the welding contact seat away from the cutting frame. The laser welding head is connected to a laser welding machine. The adjusting screw rotates to adjust the height of the spot welding frame, that is, the winding thickness of the iron sheet on the winding roller. During the process of the iron sheet winding and thickening on the winding roller, the winding roller is forced to move downward. The correction structure and the cutting mechanism synchronously move downward under the action of their own gravity until the welding contact seat moves downward and passes through the bottom of the forming pressure column and contacts the iron sheet. The pressure sensor sends a signal, the stamping cylinder stops working, and the cutting cylinder starts to work. The forming motor continues to rotate, and the laser welding head is preheated and started. When the lower end of the welding contact seat contacts the cutting fracture, the welding contact seat moves downward by the plate thickness distance of one iron sheet. The signal of the pressure sensor suddenly changes, the forming motor stops working, and the laser welding head starts to weld the fracture of the iron sheet synchronously, and the iron core coil is formed.

[0014] A forming process of an iron core coil forming device includes the following steps:

[0015] S1. Feeding and positioning: Install the unslotted iron sheet coil on the material rack, and draw the free end of the iron sheet through the gap between the pressure rods, the surface of the stamping table, and the surface of the cutting guide table in sequence, and fixedly wind it between the alignment ring grooves of the winding roller;

[0016] S2. Parameter setting: Adjust the height of the spot welding frame by rotating the adjusting screw to make the scale indicate the preset iron core coil thickness threshold, and set the welding parameters of the laser welding machine;

[0017] S3. Continuous forming:

[0018] a. Start the stamping cylinder and the forming motor. The stamping die head periodically slots the passing iron sheet, and the forming motor synchronously drives the winding roller to rotate the coil material at an angular velocity matching the slotting spacing;

[0019] b. During the winding process of the slotted iron sheet, the ball head end of the correction guide rod slides along the alignment ring groove, forcing the edges of the winding layers to align; as the winding thickness increases, the winding roller presses down to compress the first spring, and the forming pressure column continuously applies a downward pressure to keep the winding layers dense;

[0020] S4. Thickness monitoring and cutting: When the coil thickness reaches the threshold, the welding contact seat contacts the surface of the iron sheet, triggering the pressure sensor. The controller immediately stops the stamping cylinder and starts the cutting cylinder to cut the iron sheet. At the same time, the forming motor keeps running to pull the cutoff forward.

[0021] S5. Fracture welding: When the fracture moves to the bottom of the welding contact seat, the downward movement of the iron sheet triggers a sudden change in the pressure signal. The controller synchronously stops the forming motor and activates the laser welding head to spot weld the fracture to complete the core roll forming.

[0022] The present invention provides a core roll forming device and a forming process, which have the following beneficial effects:

[0023] 1. The present invention realizes the automation of the whole process of core coil from slotting, winding, thickness monitoring, cutting to welding through the mechanical linkage and electric control signal coordination of the stamping mechanism, winding drive mechanism, correction mechanism and spot welding mechanism. The cooperation of the pressure sensor and the controller realizes the real-time monitoring of the coil thickness threshold and the switching of the processing state (such as stamping stop, cutting trigger, welding start), which significantly reduces manual intervention, improves production efficiency and process consistency, and adopts the stamping-cutting-winding integrated processing method, which can avoid the problem of occupying too much space and the coil being difficult to bend and damaged due to slotting in the prior art.

[0024] 2. The present invention corrects the sliding cooperation between the guide rod and the positioning annular grooves at both ends of the roller, combined with the downward pressure of the counterweight crossbar, to continuously constrain the edge alignment of the iron sheet during the winding process to ensure that there is no misalignment between layers. The elastic suspension design of the roller (the first spring) and the constant pressure of the forming pressure column ensure that the iron sheet is always in a uniformly compressed state during the winding process, and the density of the core roll is adaptively enhanced as the thickness increases, avoiding the looseness problem caused by the gap between layers in the traditional process.

[0025] 3. The present invention uses the floating structure of the welding contact seat (the second spring and the limit column) and the pressure sensor trigger mechanism, combined with the continuous traction of the forming motor, to ensure that the cut-off fracture automatically moves to the welding station. The tilted design of the laser welding head uses the winding tension to make the fracture fit tightly, and cooperates with the instantaneous welding triggered by the sudden change of the pressure signal to solve the problem of insufficient welding strength caused by positioning deviation in traditional spot welding, and significantly improves welding accuracy and reliability.

[0026] 4. The oblique discharge hole design of the punching table in the present invention realizes the rapid and automatic discharge of the punching waste, avoiding the risk of blockage; the strict synchronous control of the punching cylinder and the forming motor (one punching corresponds to one winding unit) ensures that the slotting spacing and the winding pitch are accurately matched, eliminating the tensile deformation of the iron sheet or the slotting misalignment defects caused by the speed asynchrony in the traditional step-by-step processing.

[0027] 5. In the present invention, the cooperation between the adjusting screw and the scale allows for presetting the thickness thresholds of iron core coils of different specifications through simple operations, adapting to diverse production requirements. The follow - down design of the correction mechanism and the spot - welding mechanism (based on the downward pressure of the roll and gravity) enables the equipment to automatically maintain the relative positional relationship of the functional modules during the change of coil thickness, ensuring process stability and reducing the complexity of equipment debugging. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings of the embodiments will be briefly introduced below.

[0029] The drawings in the following description only relate to some embodiments of the present invention and do not limit the present invention.

[0030] In the drawings:

[0031] Figure 1 A first axonometric structural schematic diagram of the present invention is shown;

[0032] Figure 2 A second axonometric structural schematic diagram of the present invention is shown;

[0033] Figure 3 A third axonometric structural schematic diagram of the present invention is shown;

[0034] Figure 4 An axonometric structural schematic diagram of the present invention in the state where the forming pressure column moves upward and separates is shown;

[0035] Figure 5 An axonometric structural schematic diagram of the present invention in the semi - sectional separated state of the forming pressure column is shown;

[0036] Figure 6 An axonometric structural schematic diagram of the present invention in the state where the correction mechanism and the spot - welding mechanism are separated is shown;

[0037] Figure 7 An axonometric structural schematic diagram of the present invention in the partially disassembled state of the spot - welding mechanism is shown;

[0038] Figure 8 An illustration of the present invention's Figure 7 enlarged partial structure diagram at A;

[0039] Figure 9 An axonometric structural schematic diagram of the present invention in the state where the iron core coil is taken out is shown.

[0040] REFERENCE NUMERALS

[0041] 1. Base;

[0042] 2. Operating vertical plate; 201. Movable hole; 202. Pressing rod;

[0043] 3. Controller;

[0044] 4. Laser welding machine;

[0045] 5. Material rack;

[0046] 6. Punching frame; 601. Punching cylinder; 602. Punching die head;

[0047] 7. Punching table; 701. Discharging hole;

[0048] 8. Cutting frame; 801. Cutting cylinder; 802. Cutting knife;

[0049] 9. Cut off the guide table;

[0050] 10. Roller; 1001. Bushing block; 1002. Forming motor; 1003. Hanging rod; 1004. Fixing plate; 1005. First spring; 1006. Alignment ring groove;

[0051] 11. Forming pressure column; 1101. Counterweight cross bar; 1102. Correction guide rod; 1103. Adjustment screw; 1104. Spot welding frame; 1141. Table groove; 1142. Limit column; 1105. Ruler; 1106. Welding contact seat; 1161. Insert rod; 1162. Second spring; 1163. Laser welding head. DETAILED DESCRIPTION

[0052] In order to make the purpose, technical solution and advantages of the embodiment of the present invention clearer, the technical solution of the embodiment of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiment of the present invention. Obviously, the described embodiment is a part of the embodiment of the present invention, not all of the embodiments. Based on the described embodiment of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0053] Please refer to Figures 1 to 9 :

[0054] Embodiment 1:

[0055] The present invention provides an iron core coiling and forming device and a forming process, including: a base 1; an operation vertical plate 2 is vertically arranged at the upper end of the base 1; a controller 3 and a laser welding machine 4 are fixedly hung on the operation vertical plate 2; a material rack 5 for storing unslotted iron sheets is rotatably arranged at one end of the operation vertical plate 2, and a coiling roller 10 for coiling the slotted iron sheets is arranged at the other end of the operation vertical plate 2; a stamping mechanism and a cutting mechanism are arranged on the operation vertical plate 2 between the material rack 5 and the coiling roller 10, the stamping mechanism is close to the material rack 5, and the cutting mechanism is close to the coiling roller 10; the stamping mechanism is composed of a stamping frame 6 and a stamping table 7, and the stamping frame 6 is above the stamping table 7; the cutting mechanism is composed of a cutting frame 8 and a cutting guide table 9, and the cutting frame 8 is above the cutting guide table 9; a forming pressure column 11 is vertically and horizontally fixedly arranged on the operation vertical plate 2 directly above the coiling roller 10, a movable hole 201 is vertically arranged on the operation vertical plate 2 at the position where the coiling roller 10 is located, and the coiling roller 10 can move vertically in the movable hole 201; a rectifying mechanism is vertically arranged on the forming pressure column 11, and a spot welding mechanism is arranged on the rectifying mechanism and penetrates through the forming pressure column 11; the rectifying mechanism is composed of a counterweight cross bar 1101 and a rectifying guide rod 1102 to form a portal structure, which is used to ensure neatness during the iron core coiling and forming process; the spot welding mechanism is composed of an adjusting screw 1103, a spot welding frame 1104, a scale 1105 and a welding contact seat 1106, and the broken end is spot welded and fixed after a coil of iron core is coiled and formed.

[0056] Among them, two layers of pressing rods 202 are vertically arranged on the operation vertical plate 2 between the material rack 5 and the stamping table 7, the unslotted iron sheets pass through between the two layers of pressing rods 202, and the upper pressing rod 202 is misaligned and leans towards the material rack 5 to press the material line of the unslotted iron sheets.

[0057] Among them, the upper end of the stamping frame 6 is a vertical stamping cylinder 601, the piston rod of the stamping cylinder 601 is fixedly connected downward with a stamping die head 602, and the stamping die head 602 moves downward to slot the iron sheet passing below.

[0058] Among them, a discharge hole 701 vertically corresponding to the stamping die head 602 is vertically opened in the stamping table 7, and the lower end of the stamping table 7 at the discharge hole 701 is an inclined cutting structure outward and downward.

[0059] Among them, the middle part of the upper end of the cutting frame 8 is a vertical cutting cylinder 801, the end of the piston rod of the cutting cylinder 801 is fixedly connected vertically downward with a cutter 802, and the cutter 802 moves downward to cut the slotted iron sheet passing on the cutting guide table 9.

[0060] Among them, the upper end surfaces of the stamping table 7, the cutting guide table 9 and the lower end of the forming pressure column 11 are always on the same horizontal plane.

[0061] Among them, a sleeve block 1001 is rotatably sleeved on the rotating shaft at one end of the winding roll 10 close to the operating vertical plate 2. The sleeve block 1001 is vertically slidably clamped in the movable hole 201. A forming motor 1002 is fixedly provided at one end of the sleeve block 1001 away from the winding roll 10 for driving the winding roll 10 to rotate. A suspension rod 1003 is vertically provided at the upper end of the sleeve block 1001. The upper end of the suspension rod 1003 vertically slides through a fixing plate 1004. The fixing plate 1004 is fixedly connected to the operating vertical plate 2. A retaining disc is provided at the end of the suspension rod 1003. A first spring 1005 is sleeved on the suspension rod 1003 between the retaining disc and the fixing plate 1004. The first spring 1005 provides an upward pulling force for the sleeve block 1001 all the time. The rotation angle of the winding roll 10 driven by the forming motor 1002 is consistent with the slotting spacing of the iron sheet. Each time the stamping cylinder 601 stamps once, the forming motor 1002 winds one unit.

[0062] Among them, annular alignment ring grooves 1006 are respectively formed on the roller surfaces at both ends of the winding roll 10. Correction guide rods 1102 are respectively vertically slidably provided at positions corresponding to the alignment ring grooves 1006 at both ends of the forming pressure column 11. The lower ends of the correction guide rods 1102 are spherical structures, and the lower ends of the correction guide rods 1102 are always slidably placed in the corresponding alignment ring grooves 1006. A counterweight cross bar 1101 is arranged between the upper ends of the two correction guide rods 1102. The upper ends of the correction guide rods 1102 are vertically rotatably connected to the counterweight cross bar 1101 through a rotating shaft. The slotted iron sheet is wound on the winding roll 10 between the two alignment ring grooves 1006. The correction guide rods 1102 are tangent to the edge of the wound iron sheet. As the wound iron sheet increases, the winding roll 10 moves downward, the first spring 1005 is compressed, and the extrusion force between the iron sheet on the winding roll 10 and the forming pressure column 11 increases. The iron sheet at the bottom of the forming pressure column 11 always maintains the same height to keep the winding stable.

[0063] Embodiment 2. On the basis of Embodiment 1, the middle part of the upper end of the counterweight cross bar 1101 is vertically and rotatably connected to the adjusting screw 1103. On one side of the adjusting screw 1103, the counterweight cross bar 1101 is a vertically upward scale 1105. The middle part of the gantry-shaped spot welding frame 1104 is rotatably and screwed to the adjusting screw 1103. The upper end of the scale 1105 vertically slides through the spot welding frame 1104. The lower end of the scale 1105 is the scale zero point. The two ends of the spot welding frame 1104 vertically pass through the counterweight cross bar 1101 and pass through the lower forming pressure column 11. On one side of the lower end of the spot welding frame 1104 close to the cutting frame 8, a table groove 1141 is opened. A "T"-shaped welding contact seat 1106 is vertically slidably arranged in the table groove 1141. Two symmetrical insertion rods 1161 are vertically arranged at the upper end of the welding contact seat 1106. A second spring 1162 is sleeved on the insertion rods 1161. The insertion rods 1161 vertically slide and are inserted into the top of the table groove 1141. At the position close to the lower end of the table groove 1141, limiting columns 1142 are vertically arranged symmetrically on the left and right. The limiting columns 1142 are used to stop the welding contact seat 1106 to prevent the welding contact seat 1106 from moving down and coming out of position. A pressure sensor is arranged at the bottom of the welding contact seat 1106. On the side of the welding contact seat 1106 away from the cutting frame 8, an inclined downward laser welding head 1163 is arranged. The laser welding head 1163 is connected to the laser welding machine 4. The adjusting screw 1103 rotates to adjust the height of the spot welding frame 1104, that is, the thickness of the iron sheet that can be wound on the winding roller 10. During the process of the iron sheet being wound and thickened on the winding roller 10, the winding roller 10 is forced to move down. The correction structure and the cutting mechanism synchronously move down under the action of their own gravity until the welding contact seat 1106 moves down and passes through the bottom of the forming pressure column 11 and contacts the iron sheet. The pressure sensor sends a signal, the stamping cylinder 601 stops working, and the cutting cylinder 801 starts to work. The forming motor 1002 continues to rotate, and the laser welding head 1163 is preheated and started. When the lower end of the welding contact seat 1106 contacts the cutting break, the welding contact seat 1106 moves down a distance equal to the thickness of one iron sheet. The signal of the pressure sensor suddenly changes, the forming motor 1002 stops working, and the laser welding head 1163 starts to weld the iron sheet break synchronously, and the iron core roll is formed.

[0064] The functions and effects of the above structures are further explained and described below for those skilled in the art to better understand the technical solution of the present invention:

[0065] The base 1 and the vertically arranged operation vertical plate 2 form the main body support structure of the equipment, ensuring the spatial stability of each functional module. The material rack 5 and the winding roller 10 are arranged at both ends to form a continuous processing path. After the unslotted iron sheet is released from the material rack 5, it is pressed and guided by the upper and lower layers of staggered pressing rods 202 to prevent the material line from shifting. The staggered design of the pressing rod 202 adjusts the tension of the iron sheet through friction, ensuring the stability of material transmission in subsequent stamping and winding processes. The upper surfaces of the stamping table 7 and the cutting guide table 9 are on the same horizontal plane, and together with the bottom plane of the forming pressure column 11, they form a continuous support surface, keeping the iron sheet flat during stamping slotting, cutting, and winding processes, reducing the risk of deformation.

[0066] In the stamping mechanism, the stamping cylinder 601 drives the stamping die head 602 to periodically slot the iron sheet. The discharge hole 701 of the stamping table 7 is designed with an oblique cutting structure, facilitating the rapid discharge of stamping waste and preventing blockage. The winding roller 10 realizes vertical floating through the elastic suspension system composed of the sleeve block 1001 and the first spring 1005. When the forming motor 1002 drives the winding roller 10 to rotate, its rotation angle is strictly synchronized with the stamping frequency of the stamping cylinder 601, ensuring that each slotting pitch is consistent with the winding pitch. The ball head ends of the alignment ring grooves 1006 at both ends of the winding roller 10 are slidably matched with the correction guide rods 1102, continuously applying radial constraints to the edge of the iron sheet during winding, forcing the edges of the winding layers to align and avoiding problems such as looseness or inclination caused by misalignment between the winding layers of the iron core.

[0067] In the correction mechanism, the gantry structure composed of the counterweight cross bar 1101 and the correction guide rod 1102 provides a constant downward pressure through its own weight. As the thickness of the iron core winding increases, the winding roller 10 moves downward to compress the first spring 1005. At this time, the correction guide rod 1102 slides along the alignment ring groove 1006 and remains in contact with the edge of the winding layer, enabling the forming pressure column 11 to always apply a uniform pressure to the outermost iron sheet, ensuring the density of the winding layer. The adjustment screw 1103 of the spot welding mechanism cooperates with the scale 1105 to preset the target thickness threshold of the iron core winding by rotating to adjust the initial height of the spot welding frame 1104. When the winding thickness reaches the set value, the pressure sensor at the bottom of the welding contact seat 1106 contacts the surface of the iron sheet, triggering the controller 3 to close the stamping cylinder 601 and start the cutting cylinder 801, realizing the automatic switching of thickness monitoring and processing termination.

[0068] During the cutting process, the forming motor 1002 keeps running, so that the cut iron sheet fracture moves forward with the rotation of the winding roller 10 to below the welding contact seat 1106. The welding contact seat 1106 forms a floating contact structure through the second spring 1162 and the limit post 1142. When the fracture moves below it, the iron sheet causes the welding contact seat 1106 to move down by the thickness of one plate due to the sudden reduction of the coil thickness, and the signal mutation of the pressure sensor triggers the controller 3 to stop winding and activate the laser welding head 1163. The inclined laser welding head 1163 performs instantaneous spot welding on the fracture after preheating, and uses the winding tension of the iron sheet to make the fracture fit tightly to ensure the welding strength. The whole process realizes the full-process automation of "winding - monitoring - cutting - welding" through the precise coordination of mechanical linkage and electric control signals, significantly improving the efficiency and consistency of core coil forming.

[0069] Working principle:

[0070] Install the unslotted iron sheet coil on the material rack 5, and draw the free end of the iron sheet through the gap between the pressure rods 202, the surface of the stamping table 7, and the surface of the cutting guide table 9 in sequence, and fix it and wind it between the alignment ring grooves 1006 of the winding roller 10;

[0071] Adjust the height of the spot welding frame 1104 by rotating and adjusting the screw rod 1103, so that the scale 1105 indicates the preset threshold value of the core coil thickness, and set the welding parameters of the laser welding machine 4;

[0072] Start the stamping cylinder 601 and the forming motor 1002. The stamping die head 602 performs periodic slotting on the passing iron sheet, and the forming motor 1002 synchronously drives the winding roller 10 to rotate the coil material at an angular velocity matching the slotting pitch;

[0073] During the winding process of the slotted iron sheet, the spherical head end of the correction guide rod 1102 slides along the alignment ring groove 1006, forcing the edges of the winding layers to align; as the coil thickness increases, the winding roller 10 presses down to compress the first spring 1005, and the forming pressure post 11 continuously applies a downward pressure to keep the winding layers dense;

[0074] When the coil thickness reaches the threshold value, the welding contact seat 1106 touches the surface of the iron sheet and triggers the pressure sensor. The controller 3 immediately stops the stamping cylinder 601, starts the cutting cylinder 801 to cut the iron sheet downward, and at the same time the forming motor 1002 keeps running to pull the fracture forward;

[0075] When the fracture moves below the welding contact seat 1106, the downward movement of the iron sheet triggers a sudden change in the pressure signal. The controller 3 synchronously stops the forming motor 1002 and activates the laser welding head 1163 to perform spot welding and fixation on the fracture, completing the forming of the core coil.

[0076] In this article, the following points need attention:

[0077] 1. The attached drawings of the embodiments of the present invention only relate to the structures involved in the embodiments of the present invention, and other structures can refer to the general design.

[0078] 2. Without conflict, the embodiments of the present invention and the features in the embodiments can be combined with each other to obtain new embodiments.

[0079] The above are only the specific embodiments of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention can easily think of changes or substitutions, which should be covered by the protection scope of the present invention.

Claims

1. A core coiling and forming device, comprising: Base (1); an operation vertical plate (2) is vertically provided at the upper end of the base (1); the operation vertical plate (2) fixedly mounts a controller (3) and a laser welding machine (4); one end of the operation vertical plate (2) is rotatably provided with a material rack (5) for storing unslotted iron sheets, and a winding roller (10) for winding the slotted iron sheets is provided at the other end of the operation vertical plate (2); it is characterized in that a stamping mechanism and a cutting mechanism are provided on the operation vertical plate (2) between the material rack (5) and the winding roller (10), the stamping mechanism is close to the material rack (5), and the cutting mechanism is close to the winding roller (10); the stamping mechanism is composed of a stamping frame (6) and a stamping table (7), and the stamping frame (6) is above the stamping table (7); the cutting mechanism is composed of a cutting frame (8) and a cutting guide table (9), and the cutting frame (8) is above the cutting guide table (9); a forming pressing column (11) is vertically and horizontally fixedly provided on the operation vertical plate (2) directly above the winding roller (10), a movable hole (201) is vertically provided on the operation vertical plate (2) at the position where the winding roller (10) is located, and the winding roller (10) can move vertically in the movable hole (201); a rectifying mechanism is vertically provided on the forming pressing column (11), and a spot welding mechanism is provided on the rectifying mechanism and penetrates through the forming pressing column (11); the rectifying mechanism is composed of a gantry-like structure formed by a counterweight cross bar (1101) and rectifying guide rods (1102) for ensuring the neatness during the forming process of the iron core coil; the spot welding mechanism is composed of an adjusting screw (1103), a spot welding frame (1104), a scale (1105) and a welding contact seat (1106), and the broken port is spot welded and fixed after a coil of iron core is wound and formed.

2. The core coiling and forming device according to claim 1, characterized in that, Two layers of pressing rods (202) are vertically provided on the operation vertical plate (2) between the material rack (5) and the stamping table (7), the unslotted iron sheets pass through between the two layers of pressing rods (202), and the upper pressing rod (202) is misaligned and leans towards the material rack (5) to press the material line of the unslotted iron sheets.

3. A core coiling and forming device according to claim 1, characterized in that, The upper end of the stamping frame (6) is a vertical stamping cylinder (601), the piston rod of the stamping cylinder (601) is fixedly connected downward with a stamping die head (602), and the stamping die head (602) moves downward to slot the iron sheet passing below.

4. The core coiling and forming device according to claim 3, characterized in that, A discharge hole (701) vertically corresponding to the stamping die head (602) is vertically opened in the stamping table (7), and the lower end of the stamping table (7) at the discharge hole (701) is an inclined cutting structure outward and downward.

5. A core coiling and forming device according to claim 1, characterized in that, The middle of the upper end of the cutting frame (8) is a vertical cutting cylinder (801), the end of the piston rod of the cutting cylinder (801) is fixedly connected vertically downward with a cutter (802), and the cutter (802) moves downward to cut the slotted iron sheet passing on the cutting guide table (9).

6. The core coiling and forming device according to claim 1, characterized in that, The upper end surface of the stamping table (7), the upper end surface of the cutting guide table (9) and the lower end of the forming pressing column (11) are always on the same horizontal plane.

7. A core winding and forming device according to claim 3, characterized in that, One end of the roller (10) close to the operation vertical plate (2) is rotatably sleeved with a sleeve block (1001) on the rotating shaft. The sleeve block (1001) is vertically slidably clamped in the movable hole (201). A forming motor (1002) is fixedly arranged at one end of the sleeve block (1001) away from the roller (10) for driving the roller (10) to rotate. A suspension rod (1003) is vertically arranged at the upper end of the sleeve block (1001). The upper end of the suspension rod (1003) vertically slides through the fixing plate (1004). The fixing plate (1004) is fixedly connected to the operation vertical plate (2). A retaining disc is arranged at the end of the suspension rod (1003). A first spring (1005) is sleeved on the suspension rod (1003) between the retaining disc and the fixing plate (1004). The first spring (1005) provides an upward pulling force for the sleeve block (1001) all the time. The rotation angle of the forming motor (1002) driving the roller (10) is consistent with the slot spacing of the iron sheet. The stamping cylinder (601) stamps once, and the forming motor (1002) winds one unit.

8. A core coiling and forming device according to claim 1, wherein, Annular alignment ring grooves (1006) are respectively formed on the roller surfaces at both ends of the roller (10). Correction guide rods (1102) are respectively vertically slidably arranged at positions corresponding to the annular alignment ring grooves (1006) at both ends of the forming pressure column (11). The lower ends of the correction guide rods (1102) are spherical structures, and the lower ends of the correction guide rods (1102) are always slidably placed in the corresponding alignment ring grooves (1006). A counterweight cross bar (1101) is arranged between the upper ends of the two correction guide rods (1102). The upper ends of the correction guide rods (1102) are vertically rotatably connected to the counterweight cross bar (1101) through a rotating shaft. The iron sheet after slotting is wound on the roller (10) between the two alignment ring grooves (1006). The correction guide rods (1102) are tangent to the edge of the wound iron sheet. As the wound iron sheet increases, the roller (10) moves downward, the first spring (1005) is compressed, and the extrusion force between the iron sheet on the roller (10) and the forming pressure column (11) increases. The iron sheet at the bottom of the forming pressure column (11) always maintains the same height to keep the winding stable.

9. The core winding and forming device according to claim 1, characterized in that, The middle part of the upper end of the counterweight cross bar (1101) is vertically and rotatably connected to the adjusting screw (1103). On one side of the adjusting screw (1103), the counterweight cross bar (1101) is a vertically upward scale (1105). The middle part of the gantry-shaped spot welding frame (1104) is rotatably and screwed to the adjusting screw (1103). The upper end of the scale (1105) vertically slides through the spot welding frame (1104). The lower end of the scale (1105) is the scale zero point. The two ends of the spot welding frame (1104) vertically penetrate downward through the counterweight cross bar (1101) and through the lower forming pressure column (11). On one side of the lower end of the spot welding frame (1104) close to the cutting frame (8), a table groove (1141) is opened. A "T"-shaped welding contact seat (1106) is vertically slidably arranged in the table groove (1141). Two symmetric plug rods (1161) are vertically arranged at the upper end of the welding contact seat (1106). A second spring (1162) is sleeved on the plug rod (1161). The plug rod (1161) vertically slides and is inserted into the top of the table groove (1141). At the position close to the lower end of the table groove (1141), limiting columns (1142) are vertically arranged symmetrically on the left and right. The limiting columns (1142) are used to stop the welding contact seat (1106) to prevent the welding contact seat (1106) from moving downward and getting out of position. A pressure sensor is arranged at the bottom of the welding contact seat (1106). On the side of the welding contact seat (1106) away from the cutting frame (8), an inclined downward laser welding head (1163) is arranged. The laser welding head (1163) is connected to the laser welding machine (4). The adjusting screw (1103) rotates to adjust the height of the spot welding frame (1104), that is, the winding thickness of the iron sheet on the winding roller (10). During the process of the iron sheet winding and thickening on the winding roller (10), the winding roller (10) is forced to move downward, and the correction structure and the cutting mechanism synchronously move downward under the action of their own gravity until the welding contact seat (1106) moves downward and passes through the bottom of the forming pressure column (11) to contact the iron sheet. The pressure sensor sends a signal, the stamping cylinder (601) stops working, and the cutting cylinder (801) starts to work. The forming motor (1002) continues to rotate, and the laser welding head (1163) is preheated and started. When the lower end of the welding contact seat (1106) contacts the cutting fracture, the welding contact seat (1106) moves downward by the thickness of one iron sheet. The signal of the pressure sensor suddenly changes, the forming motor (1002) stops working, and the laser welding head (1163) synchronously starts to weld the fracture of the iron sheet, and the iron core roll is formed.

10. A forming process of a core winding forming device, applicable to the core winding forming device according to any one of claims 1 to 9, characterized in that, Including the following steps: S1. Loading and positioning: Install the unslotted iron sheet coil on the material rack (5), and pull the free end of the iron sheet through the gaps between the pressure rods (202), the surface of the stamping table (7), and the surface of the cutting guide table (9) in sequence, and fixedly wind it between the alignment ring grooves (1006) of the winding roller (10); S2. Parameter setting: Adjust the height of the spot welding frame (1104) by rotating the adjusting screw (1103) to make the scale (1105) indicate the preset iron core roll thickness threshold value, and set the welding parameters of the laser welding machine (4); S3. Continuous forming: a. Start the stamping cylinder (601) and the forming motor (1002). The stamping die head (602) performs periodic grooving on the passing iron sheet, and the forming motor (1002) synchronously drives the winding roller (10) to rotate the coil material at an angular velocity matching the grooving pitch; b. During the winding process of the grooved iron sheet, the ball head end of the rectifying guide rod (1102) slides along the alignment ring groove (1006), forcing the edges of the winding layers to align; As the winding thickness increases, the winding roller (10) presses down to compress the first spring (1005), and the forming pressure post (11) continuously applies a downward pressure to keep the winding layers dense; S4. Thickness monitoring and cutting: When the winding thickness reaches the threshold, the welding contact seat (1106) contacts the surface of the iron sheet to trigger the pressure sensor, and the controller (3) immediately stops the stamping cylinder (601), starts the cutting cylinder (801) to cut the iron sheet downward, and at the same time the forming motor (1002) keeps running to pull the fracture forward; S5. Fracture welding: When the fracture moves below the welding contact seat (1106), the downward movement of the iron sheet triggers a sudden change in the pressure signal. The controller (3) synchronously stops the forming motor (1002) and activates the laser welding head (1163) to perform spot welding on the fracture to fix it, completing the forming of the iron core coil.

Images