Manufacturing method and system for inductance type ignition coil of electronic injection type motorcycle

Abstract

The invention relates to the technical field of ignition coil manufacturing, and discloses a manufacturing method and system for an electric injection type motorcycle inductance type ignition coil, the system comprises a magnetic core assembly, a linear magnetic field excitation device, an area array electromagnetic detection unit and a control module, and the control module comprises a determination unit, a judgment unit, a correction unit and a manufacturing classification unit; the determination unit is configured to determine an initial magnetic core matching parameter according to the average inductance value; the judgment unit is configured to judge whether the coil winding of the to-be-detected ignition coil has performance abnormity or not; the correction unit is configured to correct the initial magnetic core matching parameters to obtain fine adjustment magnetic core parameters; and the manufacturing classification unit is configured to determine the manufacturing grade of the ignition coil to be detected according to the performance deviation type and quantity, and perform identification and classified packaging on qualified products. According to the invention, the magnetic core assembly can be accurately assembled, so that the performance of the ignition coil is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of ignition coil manufacturing, and in particular to a manufacturing method and system for an inductive ignition coil for an electronic fuel injection motorcycle. Background Art

[0002] With the continuous advancement of motorcycle technology, electronic fuel injection systems (EFI) have gradually become a mainstream feature. By precisely controlling fuel injection and ignition timing, EFI systems significantly improve a motorcycle's fuel economy and emissions. As a key component in EFI systems, the performance of inductive ignition coils directly impacts the motorcycle's starting, acceleration, and overall operating stability. However, traditional ignition coil manufacturing methods often suffer from complex processes, low efficiency, and inconsistent product quality, making them difficult to meet the high-precision, high-efficiency, and high-quality demands of the modern motorcycle manufacturing industry.

[0003] Therefore, it is necessary to design a manufacturing method and system for an inductive ignition coil for an electronic fuel injection type motorcycle to solve the problems existing in the current technology. Summary of the Invention

[0004] In view of this, the present invention proposes a manufacturing method and system for an inductive ignition coil for an electronic fuel injection motorcycle, aiming to solve the problems of complex process, low efficiency and unstable product quality in the current technology of ignition coil manufacturing methods.

[0005] In one aspect, the present invention provides a manufacturing system for an inductive ignition coil for an electronic fuel injection motorcycle, comprising:

[0006] A magnetic core assembly, a linear magnetic field excitation device, an array electromagnetic detection unit, and a control module, wherein the control module is connected to the magnetic core assembly, the linear magnetic field excitation device, and the array electromagnetic detection unit, and the control module includes a determination unit, a judgment unit, a correction unit, and a manufacturing classification unit; wherein,

[0007] The determining unit is configured to collect initial inductance value data of the coil windings of a plurality of ignition coils to be tested, establish an inductance data set, obtain an average inductance value of the coil windings of the ignition coils to be tested based on the inductance data set, and determine an initial core matching parameter based on the average inductance value;

[0008] The judgment unit is configured to sequentially install the magnetic core assembly into the coil winding of the ignition coil to be tested, and start the linear magnetic field excitation device to move along the axial direction of the ignition coil to be tested, while simultaneously collecting induced voltage data output by the coil winding of the ignition coil to be tested in real time, plotting a two-dimensional induced voltage distribution map based on the induced voltage data and the excitation position coordinates, and analyzing the two-dimensional induced voltage distribution map to determine whether the coil winding of the ignition coil to be tested has performance abnormalities;

[0009] The correction unit is configured to, when determining that the coil winding of the ignition coil to be tested has a performance abnormality, stop linear excitation, and arrange the planar array electromagnetic detection unit above the coil winding of the ignition coil to be tested, determine a performance deviation factor based on the induced voltage distribution diagram and the number of abnormal voltage coordinate points, determine a correction coefficient based on the performance deviation factor, and correct the initial magnetic core matching parameters to obtain fine-tuning magnetic core parameters;

[0010] The manufacturing classification unit is configured to perform core optimization assembly and coil recalibration based on the fine-tuning core parameters, and to re-enable the array electromagnetic detection unit to perform excitation testing, record the response signal change spectrum of the coil winding of the ignition coil to be tested under multi-frequency excitation, analyze the response signal change spectrum, and determine the type and quantity of performance deviations; determine the manufacturing grade of the ignition coil to be tested based on the type and quantity of performance deviations, and mark and classify and package qualified products.

[0011] Furthermore, when the determining unit determines the initial core matching parameter according to the average inductance value, the method includes:

[0012] Comparing the average inductance value with a first average inductance value and a second average inductance value, and determining the initial magnetic core matching parameter according to the comparison result; wherein the first average inductance value is smaller than the second average inductance value;

[0013] When the average inductance value is less than or equal to the first average inductance value, determining the initial magnetic core matching parameter as the first magnetic core matching parameter;

[0014] When the average inductance value is greater than the first average inductance value and less than or equal to the second average inductance value, determining the initial magnetic core matching parameter as the second magnetic core matching parameter;

[0015] When the average inductance value is greater than the second average inductance value, the initial magnetic core matching parameter is determined to be a third magnetic core matching parameter.

[0016] Furthermore, the judgment unit analyzes the two-dimensional induced voltage distribution diagram to judge whether the coil winding of the ignition coil to be tested has performance abnormality, including:

[0017] Determining a center point (X0, Y0) in the two-dimensional induced voltage distribution diagram;

[0018] Determine the neighborhood range with the central point as the center and r as the neighborhood radius;

[0019] Calculating the neighborhood average voltage based on the induced voltage values ​​of each coordinate point within the neighborhood;

[0020] The neighborhood average voltage is compared with a voltage difference threshold, and it is determined whether the coil winding of the ignition coil to be tested has performance abnormalities based on the comparison result.

[0021] Furthermore, when the judgment unit judges whether the coil winding of the ignition coil to be tested has performance abnormality according to the comparison result, it includes:

[0022] When the difference between the induced voltage at the central point and the average voltage of the neighborhood is greater than the voltage difference threshold, the central point is determined to be an abnormal voltage coordinate point;

[0023] When the number of abnormal voltage coordinate points is greater than a preset number of abnormal voltage coordinate points, it is determined that the coil winding of the ignition coil to be tested has performance abnormality.

[0024] Furthermore, when the correction unit determines the performance deviation factor according to the induced voltage distribution diagram and the number of abnormal voltage coordinate points, it includes:

[0025] determining an initial performance deviation factor according to the number of abnormal voltage coordinate points, wherein the initial performance deviation factor is proportional to the number of abnormal voltage coordinate points;

[0026] acquiring distance data between each abnormal voltage coordinate point according to the two-dimensional induced voltage distribution diagram, and calculating an average distance between the abnormal voltage coordinate points according to the distance data;

[0027] A performance deviation factor adjustment coefficient is determined according to the average distance of the abnormal voltage coordinate points, and the initial performance deviation factor is adjusted to obtain the performance deviation factor. The average distance of the abnormal voltage coordinate points is inversely proportional to the performance deviation factor adjustment coefficient.

[0028] Furthermore, the correction unit determines a correction coefficient according to the performance deviation factor, corrects the initial core matching parameters, and obtains fine-tuning core parameters, including:

[0029] Comparing the performance deviation factor with a first performance deviation factor and a second performance deviation factor, and determining the correction coefficient according to the comparison result; wherein the first performance deviation factor is less than the second performance deviation factor;

[0030] When the performance deviation factor is less than or equal to the first performance deviation factor, determining the correction coefficient to be a first correction coefficient, and taking the product of the first correction coefficient and the initial magnetic core matching parameter as the fine-tuning magnetic core parameter;

[0031] When the performance deviation factor is greater than the first performance deviation factor and less than or equal to the second performance deviation factor, determining the correction coefficient to be a second correction coefficient, and using a product value of the second correction coefficient and the initial magnetic core matching parameter as the fine-tuning magnetic core parameter;

[0032] When the performance deviation factor is greater than the second performance deviation factor, the correction coefficient is determined to be a third correction coefficient, and a product value of the third correction coefficient and the initial magnetic core matching parameter is used as the fine-tuning magnetic core parameter.

[0033] Furthermore, the manufacturing classification unit analyzes the response signal change map to determine the type and amount of performance deviation, including:

[0034] Obtaining a graph of changes in the induced voltage response of the coil winding of the ignition coil to be tested under multi-frequency excitation according to the response signal change graph;

[0035] When the fluctuation range of the response curve at a certain position in the induced voltage response change trend graph increases significantly under multiple frequencies, it is determined that the insulation layer at that position is damaged;

[0036] When a response curve at a certain position in the induced voltage response change trend diagram shows a periodic jump or a sudden change, it is determined that a magnetic core deviation exists at the position;

[0037] When the response curve of a certain position in the induced voltage response change trend diagram shows abnormal weakening or distortion in the high-frequency section, it is determined that the winding at that position is loose or broken.

[0038] Furthermore, when the manufacturing classification unit determines the manufacturing grade of the ignition coil to be tested according to the type and amount of the performance deviation, it includes:

[0039] determining a quality score of the inductive ignition coil based on the type and amount of the performance deviation;

[0040] determining a manufacturing grade of the inductive ignition coil according to the quality score;

[0041] The quality score is calculated by the following formula:

[0042] Q=1-(ω1*N1+ω2*N2+ω3*N3);

[0043] Where Q represents the quality score of the inductive ignition coil; ω1, ω2, and ω3 represent the weight coefficients of insulation damage, core deviation, and winding looseness or breakage, respectively; and N1, N2, and N3 represent the number of insulation damage, core deviation, winding looseness or breakage, respectively.

[0044] Furthermore, when the manufacturing classification unit determines the manufacturing grade of the inductive ignition coil according to the quality score, it includes:

[0045] When the quality score is ≥0.9, the manufacturing grade of the inductive ignition coil is determined to be level one;

[0046] When 0.7≤quality score<0.9, the manufacturing grade of the inductive ignition coil is determined to be level 2;

[0047] When the quality score is less than 0.7, the manufacturing grade of the inductive ignition coil is determined to be level three;

[0048] Inductive ignition coils identified as Grade III manufacturing grade will be repaired or scrapped, while inductive ignition coils identified as Grade I and Grade II manufacturing grades will be labeled and packaged in categories.

[0049] Compared with the prior art, the beneficial effects of the present invention are as follows: the manufacturing system for inductive ignition coils for electronic fuel injection motorcycles provided by the present invention improves the manufacturing accuracy and efficiency of inductive ignition coils, ensuring the quality and reliability of the products. By collecting the initial inductance value data and determining the initial core matching parameters, the core assembly can be accurately assembled, thereby improving the performance of the ignition coil. At the same time, by using a linear magnetic field excitation device and a planar array electromagnetic detection unit to perform detailed electromagnetic detection on the coil winding, performance anomalies can be discovered and corrected in a timely manner, avoiding the production of unqualified products. In addition, by determining the type and quantity of performance deviations based on the response signal change map, and determining the manufacturing grade accordingly, products can be more accurately classified and packaged to meet the needs of different customers.

[0050] In another aspect, the present invention also provides a method for manufacturing an inductive ignition coil for an electronic fuel injection motorcycle, comprising the following steps:

[0051] S100: Collecting initial inductance data of coil windings of a plurality of ignition coils to be tested to establish an inductance data set, obtaining an average inductance value of the coil windings of the ignition coils to be tested based on the inductance data set, and determining initial core matching parameters based on the average inductance value;

[0052] S200: sequentially installing the magnetic core assembly into the coil winding of the ignition coil to be tested, and starting the linear magnetic field excitation device to move along the axial direction of the ignition coil to be tested, while simultaneously collecting induced voltage data output by the coil winding of the ignition coil to be tested in real time, plotting a two-dimensional induced voltage distribution map based on the induced voltage data and the excitation position coordinates, and analyzing the two-dimensional induced voltage distribution map to determine whether the coil winding of the ignition coil to be tested has performance abnormalities;

[0053] S300: When it is determined that the coil winding of the ignition coil to be tested has a performance abnormality, the linear excitation is stopped, and the area array electromagnetic detection unit is arranged above the coil winding of the ignition coil to be tested, a performance deviation factor is determined based on the induced voltage distribution diagram and the number of abnormal voltage coordinate points, a correction coefficient is determined based on the performance deviation factor, and the initial core matching parameters are corrected to obtain fine-tuning core parameters;

[0054] S400: Optimize the core assembly and recalibrate the coil based on the fine-tuning core parameters, and re-enable the array electromagnetic detection unit to perform excitation testing, record the response signal change spectrum of the coil winding of the ignition coil to be tested under multi-frequency excitation, analyze the response signal change spectrum, and determine the type and amount of performance deviations; determine the manufacturing grade of the ignition coil to be tested based on the type and amount of performance deviations, and mark and classify and package qualified products.

[0055] It is understandable that the above-mentioned manufacturing method and system for the inductive ignition coil of the electronic fuel injection motorcycle have the same beneficial effects, and will not be described in detail here. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiment below. The accompanying drawings are for illustration purposes only and are not to be considered as limiting the present invention. The same reference symbols are used throughout the drawings to represent the same components. In the drawings:

[0057] Figure 1 A structural block diagram of a manufacturing system for an inductive ignition coil for an electronic fuel injection motorcycle provided by an embodiment of the present invention;

[0058] Figure 2 The present invention provides a flowchart of a method for manufacturing an inductive ignition coil for an electronic fuel injection motorcycle. DETAILED DESCRIPTION

[0059] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art. It should be noted that, unless there is a conflict, the embodiments of the present disclosure and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with the embodiments.

[0060] See Figure 1 As shown, in some embodiments of the present application, this embodiment provides a manufacturing system for an inductive ignition coil for an electronic fuel injection motorcycle, comprising:

[0061] A magnetic core assembly, a linear magnetic field excitation device, an array electromagnetic detection unit, and a control module, wherein the control module is connected to the magnetic core assembly, the linear magnetic field excitation device, and the array electromagnetic detection unit, and the control module includes a determination unit, a judgment unit, a correction unit, and a manufacturing classification unit; wherein,

[0062] The determining unit is configured to collect initial inductance value data of the coil windings of a plurality of ignition coils to be tested, establish an inductance data set, obtain an average inductance value of the coil windings of the ignition coils to be tested based on the inductance data set, and determine an initial core matching parameter based on the average inductance value;

[0063] The judgment unit is configured to sequentially install the magnetic core assembly into the coil winding of the ignition coil to be tested, and start the linear magnetic field excitation device to move along the axial direction of the ignition coil to be tested, while simultaneously collecting induced voltage data output by the coil winding of the ignition coil to be tested in real time, plotting a two-dimensional induced voltage distribution map based on the induced voltage data and the excitation position coordinates, and analyzing the two-dimensional induced voltage distribution map to determine whether the coil winding of the ignition coil to be tested has performance abnormalities;

[0064] The correction unit is configured to, when determining that the coil winding of the ignition coil to be tested has a performance abnormality, stop linear excitation, and arrange the planar array electromagnetic detection unit above the coil winding of the ignition coil to be tested, determine a performance deviation factor based on the induced voltage distribution diagram and the number of abnormal voltage coordinate points, determine a correction coefficient based on the performance deviation factor, and correct the initial magnetic core matching parameters to obtain fine-tuning magnetic core parameters;

[0065] The manufacturing classification unit is configured to perform core optimization assembly and coil recalibration based on the fine-tuning core parameters, and to re-enable the array electromagnetic detection unit to perform excitation testing, record the response signal change spectrum of the coil winding of the ignition coil to be tested under multi-frequency excitation, analyze the response signal change spectrum, and determine the type and quantity of performance deviations; determine the manufacturing grade of the ignition coil to be tested based on the type and quantity of performance deviations, and mark and classify and package qualified products.

[0066] In this embodiment, the magnetic core assembly is composed of multiple core units, which can be assembled according to different initial core matching parameters to accommodate different ignition coil requirements. The linear magnetic field excitation device is responsible for generating a linear magnetic field that moves along the axial direction of the ignition coil. This magnetic field can stimulate the induced voltage in the coil winding for subsequent analysis and processing. The array electromagnetic detection unit is used to perform detailed electromagnetic testing of the coil winding after the linear excitation is stopped to obtain more accurate information on the induced voltage distribution and performance deviation.

[0067] In this embodiment, the initial core matching parameters include the total core height, center column height, winding window height, center column diameter, core width, material permeability and saturation flux density, etc.

[0068] It can be understood that the manufacturing system for inductive ignition coils for electronic fuel injection motorcycles provided in this embodiment improves the manufacturing accuracy and efficiency of inductive ignition coils, ensuring the quality and reliability of the products. By collecting initial inductance value data and determining the initial core matching parameters, accurate assembly of the core components can be achieved, thereby improving the performance of the ignition coil. At the same time, detailed electromagnetic detection of the coil windings using a linear magnetic field excitation device and a planar array electromagnetic detection unit can promptly detect performance anomalies and make corrections, thereby avoiding the production of unqualified products. In addition, by determining the type and quantity of performance deviations based on the response signal change map, and determining the manufacturing grade accordingly, products can be more accurately classified and packaged to meet the needs of different customers.

[0069] Specifically, when the determining unit determines the initial magnetic core matching parameter according to the average inductance value, it includes:

[0070] Comparing the average inductance value with a first average inductance value and a second average inductance value, and determining the initial magnetic core matching parameter according to the comparison result; wherein the first average inductance value is smaller than the second average inductance value;

[0071] When the average inductance value is less than or equal to the first average inductance value, determining the initial magnetic core matching parameter as the first magnetic core matching parameter;

[0072] When the average inductance value is greater than the first average inductance value and less than or equal to the second average inductance value, determining the initial magnetic core matching parameter as the second magnetic core matching parameter;

[0073] When the average inductance value is greater than the second average inductance value, the initial magnetic core matching parameter is determined to be a third magnetic core matching parameter.

[0074] In this embodiment, the first average inductance value and the second average inductance value are obtained based on a large amount of experimental data and statistical analysis, and they represent the inductance value ranges corresponding to ignition coils of different performance levels.

[0075] It can be understood that by setting such a comparison rule, the system can automatically select appropriate initial core matching parameters according to different average inductance values, thereby improving manufacturing flexibility and automation.

[0076] Specifically, the judgment unit analyzes the two-dimensional induced voltage distribution diagram to judge whether the coil winding of the ignition coil to be tested has performance abnormality, including:

[0077] Determining a center point (X0, Y0) in the two-dimensional induced voltage distribution diagram;

[0078] Determine the neighborhood range with the central point as the center and r as the neighborhood radius;

[0079] Calculating the neighborhood average voltage based on the induced voltage values ​​of each coordinate point within the neighborhood;

[0080] The neighborhood average voltage is compared with a voltage difference threshold, and it is determined whether the coil winding of the ignition coil to be tested has performance abnormalities based on the comparison result.

[0081] In this embodiment, the two-dimensional induced voltage distribution diagram is a distribution diagram in which the horizontal axis and the vertical axis are the excitation position coordinates and the induced voltage value respectively, which can intuitively show the induced voltage response of the coil winding at different excitation positions.

[0082] In this embodiment, the neighborhood average voltage is calculated based on the induced voltage values ​​of each coordinate point within the neighborhood range by adding the induced voltage values ​​of all coordinate points and then dividing the sum by the total number of coordinate points.

[0083] As you can understand, by setting the center point (X0, Y0) and the neighborhood radius r, a neighborhood range can be determined. The induced voltage within this range reflects the performance of the coil winding at a specific location. By calculating the neighborhood average voltage and comparing it with the voltage difference threshold, it is possible to determine whether there are any performance anomalies in the coil winding.

[0084] Specifically, when the judgment unit judges whether the coil winding of the ignition coil to be tested has performance abnormality according to the comparison result, it includes:

[0085] When the difference between the induced voltage at the central point and the average voltage of the neighborhood is greater than the voltage difference threshold, the central point is determined to be an abnormal voltage coordinate point;

[0086] When the number of abnormal voltage coordinate points is greater than a preset number of abnormal voltage coordinate points, it is determined that the coil winding of the ignition coil to be tested has performance abnormality.

[0087] It can be understood that by comparing the difference between the induced voltage at the center point and the average voltage of the neighborhood, as well as counting the number of abnormal voltage coordinate points, the system can accurately identify coil windings with performance abnormalities, providing a reliable basis for subsequent corrections and optimizations.

[0088] Specifically, when the correction unit determines the performance deviation factor according to the induced voltage distribution diagram and the number of abnormal voltage coordinate points, it includes:

[0089] determining an initial performance deviation factor according to the number of abnormal voltage coordinate points, wherein the initial performance deviation factor is proportional to the number of abnormal voltage coordinate points;

[0090] acquiring distance data between each abnormal voltage coordinate point according to the two-dimensional induced voltage distribution diagram, and calculating an average distance between the abnormal voltage coordinate points according to the distance data;

[0091] A performance deviation factor adjustment coefficient is determined according to the average distance of the abnormal voltage coordinate points, and the initial performance deviation factor is adjusted to obtain the performance deviation factor. The average distance of the abnormal voltage coordinate points is inversely proportional to the performance deviation factor adjustment coefficient.

[0092] It can be understood that by comprehensively considering the number of abnormal voltage coordinate points and the distance data between them, the system can more accurately assess the degree of performance deviation of the coil winding. The initial performance deviation factor reflects the basic number of abnormal voltage coordinate points, while the average distance between abnormal voltage coordinate points provides additional information about the distribution of these abnormal points. When the abnormal voltage coordinate points are distributed more densely, the average distance is smaller, indicating that the performance deviation may be more severe. Therefore, it is necessary to appropriately adjust the initial performance deviation factor using the performance deviation factor adjustment coefficient to obtain a more accurate performance deviation factor. This enables the system to more precisely identify and address performance anomalies in the coil winding, further improving manufacturing accuracy and reliability.

[0093] Specifically, the correction unit determines a correction coefficient according to the performance deviation factor, corrects the initial core matching parameters, and obtains fine-tuning core parameters, including:

[0094] Comparing the performance deviation factor with a first performance deviation factor and a second performance deviation factor, and determining the correction coefficient according to the comparison result; wherein the first performance deviation factor is less than the second performance deviation factor;

[0095] When the performance deviation factor is less than or equal to the first performance deviation factor, determining the correction coefficient to be a first correction coefficient, and taking the product of the first correction coefficient and the initial magnetic core matching parameter as the fine-tuning magnetic core parameter;

[0096] When the performance deviation factor is greater than the first performance deviation factor and less than or equal to the second performance deviation factor, determining the correction coefficient to be a second correction coefficient, and using a product value of the second correction coefficient and the initial magnetic core matching parameter as the fine-tuning magnetic core parameter;

[0097] When the performance deviation factor is greater than the second performance deviation factor, the correction coefficient is determined to be a third correction coefficient, and a product value of the third correction coefficient and the initial magnetic core matching parameter is used as the fine-tuning magnetic core parameter.

[0098] It is understandable that by setting the first performance deviation factor and the second performance deviation factor, as well as the corresponding first correction coefficient, second correction coefficient, and third correction coefficient, the system can select the appropriate correction coefficient to correct the initial core matching parameters based on the specific value of the performance deviation factor. This correction method based on the performance deviation factor can more accurately adjust the core parameters, thereby optimizing the performance of the ignition coil. The setting of the first performance deviation factor and the second performance deviation factor is also based on a large amount of experimental data and statistical analysis. They represent the performance deviation factor range corresponding to ignition coils with different degrees of performance deviation. The setting of first correction coefficient < second correction coefficient < third correction coefficient enables the system to automatically select the appropriate correction coefficient based on different performance deviation factors, further improving the degree of automation and accuracy of manufacturing.

[0099] Specifically, the manufacturing classification unit analyzes the response signal change map to determine the type and amount of performance deviation, including:

[0100] Obtaining a graph of changes in the induced voltage response of the coil winding of the ignition coil to be tested under multi-frequency excitation according to the response signal change graph;

[0101] When the fluctuation range of the response curve at a certain position in the induced voltage response change trend diagram increases significantly under multiple frequencies, it is determined that the insulation layer at that position is damaged;

[0102] When a response curve at a certain position in the induced voltage response change trend diagram shows a periodic jump or a sudden change, it is determined that a magnetic core deviation exists at the position;

[0103] When the response curve of a certain position in the induced voltage response change trend diagram shows abnormal weakening or distortion in the high-frequency section, it is determined that the winding at that position is loose or broken.

[0104] In this embodiment, the horizontal and vertical coordinates of the response signal change graph are the excitation frequency and the induced voltage value, respectively. By analyzing the response signal change graph, the response of the coil winding under different excitation frequencies can be intuitively understood, thereby judging its performance status.

[0105] In this embodiment, the horizontal axis of the response change trend graph represents the excitation frequency, and the vertical axis represents the induced voltage value. By drawing such a graph, the induced voltage response of the coil winding under different excitation frequencies can be clearly seen, thereby determining whether there is any performance abnormality.

[0106] In this embodiment, a significant increase means that the fluctuation range of the induced voltage response under multi-frequency excitation exceeds a preset normal fluctuation range threshold. The preset normal fluctuation range threshold is derived based on extensive experimental data and statistical analysis, and represents the fluctuation range of the induced voltage response under multi-frequency excitation for an ignition coil with normal performance.

[0107] Understandably, performance deviations such as insulation damage, core misalignment, and loose or broken windings can all lead to abnormal trends in the induced voltage response. Insulation damage significantly increases the fluctuation range of the response curve at a specific location under multi-frequency excitation. This is because the damaged insulation layer fails to effectively isolate the coil winding from the external environment, leading to increased electromagnetic interference. Core misalignment can cause periodic jumps or sudden changes in the response curve. This alters the magnetic field distribution within the coil winding, thereby affecting the induced voltage output. Loose or broken windings can cause the response curve to exhibit abnormal weakening or distortion in the high-frequency range. This is because high-frequency excitation causes more dramatic changes in the electromagnetic field within the winding, which a loose or broken winding cannot effectively withstand, resulting in abnormal induced voltage output. By analyzing the response signal variation spectrum in detail, the system can accurately identify the type and number of performance deviations within the coil winding, providing important information for subsequent optimization.

[0108] Specifically, when the manufacturing classification unit determines the manufacturing grade of the ignition coil to be tested according to the type and amount of the performance deviation, it includes:

[0109] determining a quality score of the inductive ignition coil based on the type and amount of the performance deviation;

[0110] determining a manufacturing grade of the inductive ignition coil according to the quality score;

[0111] The quality score is calculated by the following formula:

[0112] Q=1-(ω1*N1+ω2*N2+ω3*N3);

[0113] Where Q represents the quality score of the inductive ignition coil; ω1, ω2, and ω3 represent the weight coefficients of insulation damage, core deviation, and winding looseness or breakage, respectively; and N1, N2, and N3 represent the number of insulation damage, core deviation, winding looseness or breakage, respectively.

[0114] It's understandable that the weighting factors ω1, ω2, and ω3 are set based on the severity of the impact of different types of performance deviation on ignition coil performance. Insulation damage directly impacts the electrical and insulation properties of the coil winding, so its weighting factor ω1 is typically set higher. While core misalignment doesn't directly damage the coil winding structure, it alters the magnetic field distribution, affecting the ignition coil's ignition efficiency and stability. Therefore, its weighting factor ω2 is also relatively high. Loose or broken windings can cause the coil winding to malfunction, having the most severe impact on ignition coil performance. Therefore, its weighting factor ω3 is typically set the highest. This weighting distribution allows the system to more accurately assess the overall quality of the ignition coil and determine its manufacturing grade based on the quality score.

[0115] Specifically, when the manufacturing classification unit determines the manufacturing grade of the inductive ignition coil according to the quality score, it includes:

[0116] When the quality score is ≥0.9, the manufacturing grade of the inductive ignition coil is determined to be level one;

[0117] When 0.7≤quality score<0.9, the manufacturing grade of the inductive ignition coil is determined to be level 2;

[0118] When the quality score is less than 0.7, the manufacturing grade of the inductive ignition coil is determined to be level three;

[0119] Inductive ignition coils identified as Grade III manufacturing grade will be repaired or scrapped, while inductive ignition coils identified as Grade I and Grade II manufacturing grades will be labeled and packaged in categories.

[0120] It is understandable that by setting clear quality scoring standards and manufacturing grade determination rules, the system can strictly control the manufacturing quality of inductive ignition coils. The first-level manufacturing grade inductive ignition coils have high quality scores and stable and reliable performance, and are suitable for high-end motorcycle products with high ignition performance requirements. Although the quality score of the second-level manufacturing grade inductive ignition coils is slightly lower, it can still meet the ignition needs of most motorcycle products and has a high cost-effectiveness. However, due to their low quality scores, the third-level manufacturing grade inductive ignition coils may have more serious performance deviations, so they need to be repaired or scrapped to avoid unqualified products from entering the market and damaging the interests of consumers. Such manufacturing grade determination rules not only improve the manufacturing quality of inductive ignition coils, but also meet the needs of different customers and enhance the market competitiveness of products.

[0121] See Figure 2 As shown, in some embodiments of the present application, this embodiment provides a method for manufacturing an inductive ignition coil for an electronic fuel injection motorcycle, comprising the following steps:

[0122] S100: Collecting initial inductance data of coil windings of a plurality of ignition coils to be tested to establish an inductance data set, obtaining an average inductance value of the coil windings of the ignition coils to be tested based on the inductance data set, and determining initial core matching parameters based on the average inductance value;

[0123] S200: sequentially installing the magnetic core assembly into the coil winding of the ignition coil to be tested, and starting the linear magnetic field excitation device to move along the axial direction of the ignition coil to be tested, while simultaneously collecting induced voltage data output by the coil winding of the ignition coil to be tested in real time, plotting a two-dimensional induced voltage distribution map based on the induced voltage data and the excitation position coordinates, and analyzing the two-dimensional induced voltage distribution map to determine whether the coil winding of the ignition coil to be tested has performance abnormalities;

[0124] S300: When it is determined that the coil winding of the ignition coil to be tested has a performance abnormality, the linear excitation is stopped, and the area array electromagnetic detection unit is arranged above the coil winding of the ignition coil to be tested, a performance deviation factor is determined based on the induced voltage distribution diagram and the number of abnormal voltage coordinate points, a correction coefficient is determined based on the performance deviation factor, and the initial core matching parameters are corrected to obtain fine-tuning core parameters;

[0125] S400: Optimize the core assembly and recalibrate the coil based on the fine-tuning core parameters, and re-enable the array electromagnetic detection unit to perform excitation testing, record the response signal change spectrum of the coil winding of the ignition coil to be tested under multi-frequency excitation, analyze the response signal change spectrum, and determine the type and amount of performance deviations; determine the manufacturing grade of the ignition coil to be tested based on the type and amount of performance deviations, and mark and classify and package qualified products.

[0126] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may take the form of a complete hardware embodiment, a complete software embodiment, or a combination of software and hardware embodiments. Furthermore, the present application may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to magnetic disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0127] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems) and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of the processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0128] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0129] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0130] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the field should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered by the scope of protection of the claims of the present invention.

Claims

1. A manufacturing system for an inductive ignition coil for an electronic fuel injection motorcycle, characterized in that: include: A magnetic core assembly, a linear magnetic field excitation device, an array electromagnetic detection unit, and a control module, wherein the control module is connected to the magnetic core assembly, the linear magnetic field excitation device, and the array electromagnetic detection unit, and the control module includes a determination unit, a judgment unit, a correction unit, and a manufacturing classification unit; wherein, The determining unit is configured to collect initial inductance value data of the coil windings of a plurality of ignition coils to be tested, establish an inductance data set, obtain an average inductance value of the coil windings of the ignition coils to be tested based on the inductance data set, and determine an initial core matching parameter based on the average inductance value; The judgment unit is configured to sequentially install the magnetic core assembly into the coil winding of the ignition coil to be tested, and start the linear magnetic field excitation device to move along the axial direction of the ignition coil to be tested, while simultaneously collecting induced voltage data output by the coil winding of the ignition coil to be tested in real time, plotting a two-dimensional induced voltage distribution map based on the induced voltage data and the excitation position coordinates, and analyzing the two-dimensional induced voltage distribution map to determine whether the coil winding of the ignition coil to be tested has performance abnormalities; The correction unit is configured to, when determining that the coil winding of the ignition coil to be tested has a performance abnormality, stop linear excitation, and arrange the planar array electromagnetic detection unit above the coil winding of the ignition coil to be tested, determine a performance deviation factor based on the induced voltage distribution diagram and the number of abnormal voltage coordinate points, determine a correction coefficient based on the performance deviation factor, and correct the initial magnetic core matching parameters to obtain fine-tuning magnetic core parameters; The manufacturing classification unit is configured to perform core optimization assembly and coil recalibration based on the fine-tuning core parameters, and to re-enable the array electromagnetic detection unit to perform excitation testing, record the response signal change spectrum of the coil winding of the ignition coil to be tested under multi-frequency excitation, analyze the response signal change spectrum, and determine the type and quantity of performance deviations; determine the manufacturing grade of the ignition coil to be tested based on the type and quantity of performance deviations, and mark and classify and package qualified products.

2. The manufacturing system for the inductive ignition coil for electronic fuel injection motorcycle according to claim 1, characterized in that: When the determining unit determines the initial magnetic core matching parameter according to the average inductance value, it includes: Comparing the average inductance value with a first average inductance value and a second average inductance value, and determining the initial magnetic core matching parameter according to the comparison result; wherein the first average inductance value is smaller than the second average inductance value; When the average inductance value is less than or equal to the first average inductance value, determining the initial magnetic core matching parameter as the first magnetic core matching parameter; When the average inductance value is greater than the first average inductance value and less than or equal to the second average inductance value, determining the initial magnetic core matching parameter as the second magnetic core matching parameter; When the average inductance value is greater than the second average inductance value, the initial magnetic core matching parameter is determined to be a third magnetic core matching parameter.

3. The manufacturing system for the inductive ignition coil for electronic fuel injection motorcycle according to claim 2, characterized in that: The determination unit analyzes the two-dimensional induced voltage distribution diagram to determine whether the coil winding of the ignition coil to be tested has performance abnormalities, including: Determining a center point (X0, Y0) in the two-dimensional induced voltage distribution diagram; Determine the neighborhood range with the central point as the center and r as the neighborhood radius; Calculating the neighborhood average voltage based on the induced voltage values ​​of each coordinate point within the neighborhood; The neighborhood average voltage is compared with a voltage difference threshold, and it is determined whether the coil winding of the ignition coil to be tested has performance abnormalities based on the comparison result.

4. The manufacturing system for the inductive ignition coil for electronic fuel injection motorcycle according to claim 3, characterized in that: When the judgment unit judges whether the coil winding of the ignition coil to be tested has performance abnormality according to the comparison result, it includes: When the difference between the induced voltage at the central point and the average voltage of the neighborhood is greater than the voltage difference threshold, the central point is determined to be an abnormal voltage coordinate point; When the number of abnormal voltage coordinate points is greater than a preset number of abnormal voltage coordinate points, it is determined that the coil winding of the ignition coil to be tested has performance abnormality.

5. The manufacturing system for the inductive ignition coil for electronic fuel injection motorcycle according to claim 4, characterized in that: When the correction unit determines the performance deviation factor according to the induced voltage distribution diagram and the number of abnormal voltage coordinate points, it includes: determining an initial performance deviation factor according to the number of abnormal voltage coordinate points, wherein the initial performance deviation factor is proportional to the number of abnormal voltage coordinate points; acquiring distance data between each abnormal voltage coordinate point according to the two-dimensional induced voltage distribution diagram, and calculating an average distance between the abnormal voltage coordinate points according to the distance data; A performance deviation factor adjustment coefficient is determined according to the average distance of the abnormal voltage coordinate points, and the initial performance deviation factor is adjusted to obtain the performance deviation factor. The average distance of the abnormal voltage coordinate points is inversely proportional to the performance deviation factor adjustment coefficient.

6. The manufacturing system for the inductive ignition coil for electronic fuel injection motorcycle according to claim 5, characterized in that: The correction unit determines a correction coefficient according to the performance deviation factor, corrects the initial magnetic core matching parameters, and obtains fine-tuning magnetic core parameters, including: Comparing the performance deviation factor with a first performance deviation factor and a second performance deviation factor, and determining the correction coefficient according to the comparison result; wherein the first performance deviation factor is less than the second performance deviation factor; When the performance deviation factor is less than or equal to the first performance deviation factor, determining the correction coefficient to be a first correction coefficient, and taking the product of the first correction coefficient and the initial magnetic core matching parameter as the fine-tuning magnetic core parameter; When the performance deviation factor is greater than the first performance deviation factor and less than or equal to the second performance deviation factor, determining the correction coefficient to be a second correction coefficient, and using a product value of the second correction coefficient and the initial magnetic core matching parameter as the fine-tuning magnetic core parameter; When the performance deviation factor is greater than the second performance deviation factor, the correction coefficient is determined to be a third correction coefficient, and a product value of the third correction coefficient and the initial magnetic core matching parameter is used as the fine-tuning magnetic core parameter.

7. The manufacturing system for the inductive ignition coil for an electronic fuel injection motorcycle according to claim 6, characterized in that: The manufacturing classification unit analyzes the response signal change map to determine the type and amount of performance deviation, including: Obtaining a graph of changes in the induced voltage response of the coil winding of the ignition coil to be tested under multi-frequency excitation according to the response signal change graph; When the fluctuation range of the response curve at a certain position in the induced voltage response change trend diagram increases significantly under multiple frequencies, it is determined that the insulation layer at that position is damaged; When a response curve at a certain position in the induced voltage response change trend diagram shows a periodic jump or a sudden change, it is determined that a magnetic core deviation exists at the position; When the response curve of a certain position in the induced voltage response change trend diagram shows abnormal weakening or distortion in the high-frequency section, it is determined that the winding at that position is loose or broken.

8. The manufacturing system for the inductive ignition coil for electronic fuel injection motorcycle according to claim 7, characterized in that: The manufacturing classification unit determines the manufacturing grade of the ignition coil to be tested according to the type and amount of the performance deviation, including: determining a quality score of the inductive ignition coil based on the type and amount of the performance deviation; determining a manufacturing grade of the inductive ignition coil according to the quality score; The quality score is calculated by the following formula: Q=1-(ω1*N1+ω2*N2+ω3*N3); Where Q represents the quality score of the inductive ignition coil; ω1, ω2, and ω3 represent the weight coefficients of insulation damage, core deviation, and winding looseness or breakage, respectively; and N1, N2, and N3 represent the number of insulation damage, core deviation, winding looseness or breakage, respectively.

9. The manufacturing system for the inductive ignition coil for electronic fuel injection motorcycle according to claim 8, characterized in that: When the manufacturing classification unit determines the manufacturing grade of the inductive ignition coil according to the quality score, the method includes: When the quality score is ≥0.9, the manufacturing grade of the inductive ignition coil is determined to be level one; When 0.7≤quality score<0.9, the manufacturing grade of the inductive ignition coil is determined to be level 2; When the quality score is less than 0.7, the manufacturing grade of the inductive ignition coil is determined to be level three; Inductive ignition coils identified as Grade III manufacturing grade will be repaired or scrapped, while inductive ignition coils identified as Grade I and Grade II manufacturing grades will be labeled and packaged in categories.

10. A method for manufacturing an inductive ignition coil for an electronic fuel injection motorcycle, applied to a manufacturing system for an inductive ignition coil for an electronic fuel injection motorcycle as claimed in any one of claims 1 to 9, characterized in that: include: Collecting initial inductance value data of the coil windings of a plurality of ignition coils to be tested to establish an inductance data set, obtaining an average inductance value of the coil windings of the ignition coils to be tested based on the inductance data set, and determining initial core matching parameters based on the average inductance value; The magnetic core assembly is sequentially installed into the coil winding of the ignition coil to be tested, and the linear magnetic field excitation device is activated to move along the axial direction of the ignition coil to be tested, while simultaneously collecting induced voltage data output by the coil winding of the ignition coil to be tested in real time, plotting a two-dimensional induced voltage distribution diagram based on the induced voltage data and the excitation position coordinates, and analyzing the two-dimensional induced voltage distribution diagram to determine whether the coil winding of the ignition coil to be tested has performance abnormalities; When it is determined that the coil winding of the ignition coil to be tested has a performance abnormality, the linear excitation is stopped, and the planar array electromagnetic detection unit is arranged above the coil winding of the ignition coil to be tested, a performance deviation factor is determined based on the induced voltage distribution diagram and the number of abnormal voltage coordinate points, a correction coefficient is determined based on the performance deviation factor, and the initial magnetic core matching parameters are corrected to obtain fine-tuning magnetic core parameters; performing core optimization assembly and coil recalibration based on the fine-tuned core parameters, and reactivating the area array electromagnetic detection unit to perform an excitation test, recording a response signal variation spectrum of the coil winding of the ignition coil to be tested under multi-frequency excitation, and analyzing the response signal variation spectrum to determine the type and amount of performance deviation; The manufacturing grade of the ignition coil to be tested is determined according to the type and quantity of the performance deviation, and qualified products are marked and packaged in categories.

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