Automatic winding apparatus and method for pancake coil

Abstract

The present invention relates to the technical field of transformer coil winding. Particularly disclosed are an automatic winding apparatus and method for a pancake coil. The apparatus comprises: a winding device which comprises a driving motor and a vertical winding die, wherein the driving motor is in driving connection with the vertical winding die; and a wire conveying device which comprises a first lifting / lowering structure, a second lifting / lowering structure, and a wire conveying frame, wherein the wire conveying frame is rotatably mounted on the first lifting / lowering structure and the second lifting / lowering structure. By means of the change difference between the lifting height of the first lifting / lowering structure and the lifting height of the second lifting / lowering structure for the wire conveying frame, the wire conveying frame has a horizontal wire outlet direction and a downward inclined wire outlet direction, and the wire conveying frame is driven by a radial driving element to move in the radial direction relative to the vertical winding die, so as to ensure that the radial distance between the wire conveying frame and each turn of wires is matched, the winding requirement of reverse pancake coils is met, and one-time winding of forward pancake coils and reverse pancake coils can be achieved by changing the wire conveying inclination angle of wires.

Description

Automatic winding device and method for pancake coils Technical Field

[0001] The present invention relates to the technical field of transformer coil winding, and in particular to an automatic winding device and method for a pancake coil. Background Art

[0002] The transformer's circuitry consists of windings, wound from copper or aluminum conductors with high electrical conductivity. Windings must possess sufficient insulation strength, mechanical strength, and heat resistance. Windings are generally classified into two types: layer windings and pancake windings. Layer windings are those where the turns are arranged continuously along the axial direction. Pancake windings are those where the turns are wound continuously along the radial direction to form a pancake, with multiple pancakes arranged axially. These types include continuous windings, capacitor-inserted windings, and tangled windings.

[0003] The coils of continuous pancake winding are divided into positive pancake coils and negative pancake coils. The positive pancake coils are wound from the inner layer to the outer layer, and the negative pancake coils are wound from the outer layer to the inner layer. When winding with a winding machine, since the winding directions of the positive pancake coils and the negative pancake coils are different, it becomes a technical challenge to directly and continuously complete the winding of a positive pancake coil and a negative pancake coil using a winding machine.

[0004] The application number is CN202210749513.7, and the patent name is "Continuous Pancake Coil Winding Method and Device". In order to achieve simultaneous winding of positive and negative pancakes, a movable spindle box and a pre-winding disk are set, and the wire of the negative pancake coil is wound on the pre-winding disk. The movable spindle box drives the pre-winding disk to surround the winding die and rotate at a speed greater than the speed of the winding die, thereby winding the wire in reverse on the winding die, and continuously and efficiently achieving the simultaneous and one-time winding of the positive and negative pancakes of the double-pancake coil.

[0005] However, for the vertical winding mold, the winding of the positive cake coil requires the conveying of horizontal wires from the inner layer to the outer layer, while the winding of the reverse cake coil requires the conveying of wires diagonally downward from the outer layer to the inner layer. There is currently no detailed one-time winding solution. For example: the application number is CN202020967811.X, and the patent name is a utility model patent for a device for reverse cake winding with continuous winding. Its background technology points out that for the horizontal winding machine, the positive cake is formed by winding the wire from the inner diameter side of the winding to the outer diameter side. The winding is relatively simple. As the winding machine rotates, the employee can complete the winding of the positive cake by holding the wire; the reverse cake is formed by winding the wire from the outer diameter side of the winding to the inner diameter side of the winding. The existing technology cannot be completed directly by the winding machine. A temporary wire cake (temporary positive cake) must be wound first, and then the temporary wire cake must be turned into a reverse cake by turning the wire. For vertical winding machines, the winding method of the positive cake is the same as that of the horizontal winding machine. However, since the winding machine is placed vertically, the reverse cake cannot be wound directly. This patent designs a wire turning plate as an auxiliary tooling to wind the reverse cake, but the auxiliary tooling needs to be installed and disassembled during the winding process.

[0006] Therefore, the present invention proposes an automatic pancake coil winding device and method, which realizes the one-time winding of the positive pancake coil and the negative pancake coil by changing the wire transmission inclination angle of the wire.

[0007] Summary of the Invention

[0008] The main purpose of the present invention is to provide an automatic winding device and method for pancake coils, which can realize the one-time winding of positive pancake coils and negative pancake coils by changing the wire transmission inclination angle of the wire.

[0009] In order to achieve the above object, the technical solutions of the present invention are:

[0010] The present invention provides a pancake coil automatic winding device, comprising:

[0011] A winding device comprising a drive motor and a vertical winding die, wherein the drive motor is drivingly connected to the vertical winding die;

[0012] A wire feeding device comprising a first lifting structure, a second lifting structure and a wire feeding frame, wherein the wire feeding frame is rotatably mounted on the first lifting structure and the second lifting structure;

[0013] After each layer of wire coils is wound, the first lifting structure and the second lifting structure jointly drive the wire feeder to rise and place the wire feeder in a positive coil feeding state or a reverse coil feeding state;

[0014] When the wire feeding frame is in the normal wire feeding state, the wire feeding direction of the wire feeding frame is set horizontally;

[0015] When the wire feeding frame is in the reversed wire feeding state, the wire feeding frame is arranged in an obliquely downward direction;

[0016] A radial driving element is installed on the wire feeding frame, and the wire feeding frame performs radial reciprocating motion relative to the vertical winding mold under the action of the radial driving element; when winding the inverted pancake coil, each time the wire is wound around one circle, the radial driving element drives the wire feeding frame to a certain distance close to the vertical winding mold.

[0017] Compared with the prior art, the present invention provides an automatic pancake coil winding device, which can realize the one-time winding of positive pancake coils and negative pancake coils by changing the wire transmission inclination angle of the wire. It has a high degree of automation and does not require the use of detachable auxiliary tooling.

[0018] The present invention installs the wire feeding frame on the first lifting structure and the second lifting structure at the same time, and utilizes the difference in the lifting height of the wire feeding frame by the first lifting structure and the second lifting structure to make the wire feeding frame have a horizontal wire outlet direction and a downward inclined wire outlet direction. When the wire outlet direction of the wire feeding frame is horizontal, it can meet the winding requirements of the wire entry angle of the positive pancake coil; when the wire outlet direction of the wire feeding frame is obliquely downward, it can facilitate the winding of the reverse pancake coil, and the radial driving element drives the wire feeding frame to move radially relative to the vertical winding mold. When winding the reverse pancake coil, each time the wire is wound around, the radial driving element drives the wire feeding frame to a certain distance close to the vertical winding mold to ensure that the radial distance between the wire feeding frame and each turn of the wire is adapted to meet the winding requirements of the reverse pancake coil.

[0019] In a preferred embodiment, a wire outlet guide wheel is provided on the side of the wire feeder close to the vertical winding mold; a wire drum is provided on the side of the wire feeder away from the vertical winding mold; and an intermediate guide wheel is provided between the wire drum and the wire outlet guide wheel.

[0020] In a preferred embodiment, the wire outlet guide wheel is an electric roller pair, which includes two electric rollers arranged in parallel; the forward rotation speed of the electric roller pair is adapted to the rotation speed of the vertical winding mold; each time a layer of inverted pancake coil is wound, the vertical winding mold stops rotating and the electric roller reverses.

[0021] In a preferred embodiment, the pancake coil automatic winding device further includes a bending device to bend the wire upward for transition between the positive pancake coil and the negative pancake coil; the bending device includes:

[0022] A lifting drive component, which is fixed on the wire transmission frame;

[0023] A bending movable head connected to the lifting drive member;

[0024] A bending fixed head, which is arranged above the bending movable head;

[0025] The movable bending head and the fixed bending head are respectively provided with opposite bending grooves. When the wire feeding frame is feeding the wire to the vertical winding die, the wire passes between the movable bending head and the fixed bending head.

[0026] In a preferred embodiment, the pancake coil automatic winding equipment further includes an insulation wrapping device, which is arranged on the wire transmission rack and located on the wire outlet side of the bending device.

[0027] In a preferred embodiment, the insulation wrapping device includes an insulation tape winding machine having a C-shaped winding area, the C-shaped winding area is located outside the transmission frame, and the transported wires are inserted into the C-shaped winding area.

[0028] In a preferred embodiment, the pancake coil automatic winding device further includes an outer diameter limiting device for flattening the coil, and the outer diameter limiting device includes:

[0029] The third lifting structure and the fourth lifting structure are evenly distributed on the outside of the vertical winding mold together with the first lifting structure;

[0030] A rotating ring frame is sleeved on the vertical winding mold and is connected to the first, third and fourth lifting structures and is arranged below the wire conveying frame. A bearing is provided on the annular surface of the rotating ring frame;

[0031] A plurality of outer diameter limiting components are arranged on the bearing surface and are evenly distributed circumferentially along the vertical winding die;

[0032] When the coil is wound, the outer diameter limiting component is lifted and radially pressed on the coil under the joint action of the first, third and fourth lifting structures.

[0033] In a preferred embodiment, the outer diameter limiting assembly includes:

[0034] An outer diameter limiting member includes a flattening portion that contacts the coil; an arc portion extending outward is provided at an upper end of the flattening portion;

[0035] a rotating rod, one end of which is hinged to the bearing surface, and the other end of which is hinged to the outer diameter limiter;

[0036] A spring has one end connected to the bearing surface and the other end connected to the rotating rod.

[0037] The present invention also provides a pancake coil automatic winding method, which is applied to a pancake coil automatic winding device, and the method comprises the following steps:

[0038] S0. Provide a wire reel to store the wire, and insert the wire end into the middle guide wheel, bending device and electric roller pair in sequence, and finally connect it to the vertical winding mold;

[0039] S1. After completing step S0, the wire feeding frame is horizontally arranged in a wire-outgoing direction under the action of the first lifting structure and the second lifting structure, and is in a normal wire-entry state; the vertical winding mold and the electric roller pair rotate forward, and the wire is wound into a normal wire coil on the vertical winding mold under the action of the rotation of the vertical winding mold;

[0040] S2. After completing step S1, when the bending device detects that the length of the wire conveyed is just enough to wind one layer of wire coil, the vertical winding die and the electric roller pair stop rotating, and the lifting drive member of the bending device drives the bending movable head and the bending fixed head to close together, so as to bend the wire located between the bending movable head and the bending fixed head;

[0041] S3. After completing step S2, the lifting drive member is reset to drive the bending movable head away from the bending fixed head;

[0042] S4. After completing step S3, the vertical winding die and the electric roller pair rotate forward at the same time; when the bobbin is just wound, the vertical winding die and the electric roller pair stop rotating at the same time, thereby completing the winding of the bobbin coil;

[0043] S5. After completing step S4, the wire feeder frame rises to a certain height under the action of the first lifting structure and the second lifting structure, and the wire outlet direction of the wire feeder frame is tilted downward; the vertical winding die and the electric roller pair rotate forward simultaneously, and the wire is reversely wound on the vertical winding die under the action of the vertical winding die and the electric roller pair; each time the wire is wound around, the radial drive element drives the wire feeder frame to a certain distance closer to the vertical winding die;

[0044] S6. After completing step S5, when the bending device detects that the length of the wire is just enough to wind one layer of wire coil, the vertical winding die and the electric roller pair stop rotating, and the lifting drive member of the bending device drives the bending movable head and the bending fixed head to close together, so as to bend the wire located between the bending movable head and the bending fixed head;

[0045] S7. After completing step S6, the lifting drive member is reset, driving the bending movable head away from the bending fixed head; the vertical winding die and the electric roller pair continue to rotate forward at the same time. When the bent portion of the wire is just wound into an inverted pancake coil, the vertical winding die stops rotating and the electric roller pair flips over to tighten the inverted pancake coil;

[0046] S8. After completing step S7, the electric roller pair stops rotating, and the wire feeder frame is moved to the next preset position under the action of the first lifting structure and the second lifting structure, so that the wire output direction of the wire feeder frame is set horizontally, preparing for the next winding of the positive coil, thereby cycling the winding action of the positive coil and the reverse coil;

[0047] S9. When it is detected that all coils are wound, the operation stops.

[0048] In a preferred embodiment, during the coil winding process, an outer diameter limiter is used to radially press the outer periphery of the wound coil, so that the outer diameter of the coil is made flat as a whole; when a positive pancake coil needs to be wound, the outer diameter limiter is set lower than the topmost coil; when a negative pancake coil needs to be wound, the outer diameter limiter is set higher than the topmost coil.

[0049] For better understanding and implementation, the present invention is described in detail below in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0051] Figure 1 is a schematic diagram of the three-dimensional structure of a pancake coil automatic winding device;

[0052] Figure 2 is an enlarged view of A in Figure 1;

[0053] FIG3 is a schematic diagram of the three-dimensional structure of the pancake coil automatic winding equipment from another perspective;

[0054] FIG4 is an enlarged view of B in FIG3 ;

[0055] Figure 5 is a schematic structural diagram of the transmission frame in the normal state of the line;

[0056] Figure 6 is a schematic structural diagram of the line transmission rack in the reversed pancake line state;

[0057] FIG7 is a schematic diagram of the partial structure of the outer diameter limiting device.

[0058] Description of reference numerals:

[0059] 11 driving motor, 12 vertical winding die, 21 first lifting structure, 22 second lifting structure, 23 wire feeding frame, 24 radial driving element, 25 support plate, 31 outlet guide wheel, 32 wire drum, 33 intermediate guide wheel, 4 bending device, 41 lifting driving part, 42 bending movable head, 43 bending fixed head, 44 bending groove, 5 insulation wrapping device, 61 third lifting structure, 62 fourth lifting structure, 63 rotating ring frame, 64 bearing, 65 outer diameter limit assembly, 651 outer diameter limit part, 652 leveling part, 653 rotating rod, 654 spring, 655 arc part, 656 roller, 657 rubber track. DETAILED DESCRIPTION

[0060] In order to better illustrate the present invention, the present invention is described in further detail below with reference to the accompanying drawings.

[0061] It should be clear that the embodiments described are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments of the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the embodiments of the present application.

[0062] The terms used in the embodiments of the present application are for the purpose of describing specific embodiments only and are not intended to limit the embodiments of the present application. The singular forms "a," "the," and "the" used in the embodiments of the present application and the appended claims are also intended to include plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any or all possible combinations of one or more associated listed items.

[0063] In the description of the present invention, it should be understood that the terms "vertical", "lateral", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the protection content of the present invention.

[0064] 1 to 7 , the present invention provides a pancake coil automatic winding device, comprising:

[0065] The winding device comprises a driving motor 11 and a vertical winding die 12, wherein the driving motor 11 is drivingly connected to the vertical winding die 12;

[0066] A wire feeding device, comprising a first lifting structure 21, a second lifting structure 22 and a wire feeding frame 23, wherein the wire feeding frame 23 is rotatably mounted on the first lifting structure 21 and the second lifting structure 22;

[0067] After each layer of wire coils is wound, the first lifting structure 21 and the second lifting structure 22 jointly drive the wire feeding frame 23 to rise and place the wire feeding frame 23 in a positive coil feeding state or a reverse coil feeding state.

[0068] When the wire feeding frame 23 is in the normal wire feeding state, the wire feeding direction of the wire feeding frame 23 is set horizontally;

[0069] When the wire feeding frame 23 is in the reversed wire feeding state, the wire feeding direction of the wire feeding frame 23 is set obliquely downward;

[0070] A radial driving element 24 is installed on the wire feeding frame 23, and the wire feeding frame 23 performs radial reciprocating motion relative to the vertical winding mold 12 under the action of the radial driving element 24; when winding the inverted pancake coil, each time the wire is wound around one circle, the radial driving element 24 drives the wire feeding frame 23 to a certain distance close to the vertical winding mold 12.

[0071] Compared with the prior art, the present invention provides an automatic pancake coil winding device, which can realize the one-time winding of positive pancake coils and negative pancake coils by changing the wire transmission inclination angle of the wire. It has a high degree of automation and does not require the use of detachable auxiliary tooling.

[0072] The present invention installs the wire feeding frame 23 on the first lifting structure 21 and the second lifting structure 22 at the same time, and utilizes the difference in the lifting height of the wire feeding frame 23 by the first lifting structure 21 and the second lifting structure 22 to make the wire feeding frame 23 have a horizontal wire outlet direction and a downward inclined wire outlet direction. When the wire outlet direction of the wire feeding frame 23 is horizontal, it can meet the winding requirements of the wire entry angle of the positive pancake coil; when the wire outlet direction of the wire feeding frame 23 is obliquely downward, it can facilitate the winding of the reverse pancake coil, and the radial driving element 24 drives the wire feeding frame 23 to move radially relative to the vertical winding mold 12. When winding the reverse pancake coil, each time the wire is wound around, the radial driving element 24 drives the wire feeding frame 23 to a certain distance close to the vertical winding mold 12 to ensure that the radial distance between the wire feeding frame 23 and each turn of the wire is adapted to meet the winding requirements of the reverse pancake coil.

[0073] In one embodiment, in order to make the line feeding frame 23 rotatably installed on the first lifting structure 21 and the second lifting structure 22 at the same time, a support plate 25 is provided between the line feeding frame 23 and the first lifting structure 21 and the second lifting structure 22, and the radial drive element 24 is installed on the back of the support plate 25 and is arranged through the support plate 25 and is driven and connected to the support frame; one end of the support plate 25 is rotatably connected to the driving end of the first lifting structure 21, and a rotating support member (not shown) is provided between the other end of the support plate 25 and the driving end of the second lifting structure 22, the rotating support member is rotatably connected to the driving end of the second lifting structure 22 and has an interlaced channel, the other end of the support plate 25 is movably arranged on the interlaced channel, and the interlaced channel provides enough moving space for the tilting of the line feeding frame 23. During the lifting process, the rotating support member acts as a follower support for the support plate 25. Specifically, as shown in FIG7 , when the lifting height of the second lifting structure 22 is greater than the lifting height of the first lifting structure 21 , the other end of the support plate 25 is lifted obliquely upward under the action of the rotating support member, and thus the support frame is lifted obliquely upward.

[0074] In one embodiment, as shown in Figures 1 to 4, a wire outlet guide wheel 31 is provided on the side of the wire delivery rack 23 close to the vertical winding mold 12; a wire drum 32 is provided on the side of the wire delivery rack 23 away from the vertical winding mold 12; an intermediate guide wheel 33 is provided between the wire drum 32 and the wire outlet guide wheel 31 to guide the wire so that the wire can be transported stably.

[0075] Furthermore, as shown in Figures 3 and 4, the wire-out guide wheel 31 is an electric roller pair, which includes two electric rollers arranged in parallel, and the wire is passed through the two electric rollers; the forward rotation speed of the electric roller pair is adapted to the rotation speed of the vertical winding mold 12; when winding the coil, the electric roller pair rotates forward to feed the wire to the vertical winding mold; each time a layer of inverted pancake coil is wound, the vertical winding mold 12 stops rotating, and the electric roller reverses to tighten the loose inverted pancake coil, so that each turn of the wire of the inverted pancake coil is close to each other without looseness or gaps.

[0076] In one embodiment, as shown in FIG1 and FIG2 , the pancake coil automatic winding device further includes a bending device 4 to bend the wire upward for transition between the positive pancake coil and the negative pancake coil; the bending device 4 includes:

[0077] A lifting drive member 41, which is fixed on the wire transmission frame 23;

[0078] A bending movable head 42 connected to the lifting drive member 41;

[0079] A bending fixed head 43, which is arranged above the bending movable head 42;

[0080] The movable bending head 42 and the fixed bending head 43 are respectively provided with corresponding bending grooves 44. When the wire feeding frame 23 is feeding the wire to the vertical winding mold 12, the wire passes between the movable bending head 42 and the fixed bending head 43. When bending, the lifting drive member 41 drives the movable bending head 42 to descend and close toward the fixed bending head 43. The wire is bent and deformed upward under the action of the bending groove 44, so that the wire coil of each layer can continue to extend upward and be wound after the winding is completed.

[0081] Furthermore, as shown in Figure 3, since bending may cause damage to the wire, the pancake coil automatic winding equipment also includes an insulation wrapping device 5, which is arranged on the wire transmission rack 23 and located on the outgoing side of the bending device 4. It can wrap the bent wire and play a role in strengthening the insulation of the wire.

[0082] Preferably, the insulation wrapping device 5 includes an insulation tape winding machine having a C-shaped winding area, through which the conveyed wire is inserted. The insulation tape on the C-shaped winding area continuously rotates to wrap the bent wire. The C-shaped winding area is located outside the wire transmission frame 23, which can prevent the wound insulation tape from being damaged by friction on the outlet guide wheel 31, further preventing damage to the wire. The insulation tape winding machine is an existing device for wrapping wires.

[0083] In one embodiment, as shown in FIG1 to FIG7 , the pancake coil automatic winding device further includes an outer diameter limiting device for flattening the coil, and the outer diameter limiting device includes:

[0084] The third lifting structure 61 and the fourth lifting structure 62 are evenly distributed on the outside of the vertical winding mold 12 together with the first lifting structure 21;

[0085] A rotating ring frame 63 is sleeved on the vertical winding mold 12 and is connected to the first, third and fourth lifting structures and is arranged below the wire conveying frame 23. A bearing 64 is provided on the annular surface of the rotating ring frame 63;

[0086] A plurality of outer diameter limiting components 65, which are arranged on the bearing surface and uniformly distributed circumferentially along the vertical winding mold 12;

[0087] When winding the coil, the outer diameter limiter 651 assembly is lifted and radially pressed against the coil under the joint action of the first, third, and fourth lifting structures. During the coil winding process, since the rotating ring frame 63 is simultaneously connected to the first, third, and fourth lifting structures, the rotating ring frame 63 rises synchronously with the coil; and since the annular surface of the rotating ring frame 63 is provided with a bearing 64, the outer diameter limiter assembly 65 is provided on the rotating ring frame 63 and radially presses against the coil. Therefore, when the vertical winding die 12 rotates, it drives the multiple outer diameter limiter assemblies 65 to rotate, providing power for the rotation of the multiple outer diameter limiter assemblies 65. Moreover, due to the friction between the multiple outer diameter limiter assemblies 65 and the coil, the rotation speed of the multiple outer diameter limiter assemblies 65 is lower than the rotation speed of the vertical winding die 12, resulting in a speed difference. Therefore, the uniform arrangement of the multiple outer diameter limiter assemblies 65 can continuously press the coil on the vertical winding die 12 360 degrees.

[0088] Furthermore, as shown in FIG7 , in order to enable the outer diameter limiting assembly 65 to maintain radial pressure on the coil, the outer diameter limiting assembly 65 includes:

[0089] The outer diameter limiting member 651 includes a flattening portion 652 that contacts the coil, and an arc portion 655 extending outward is provided at the upper end of the flattening portion 652;

[0090] A rotating rod 653, one end of which is hinged to the bearing surface, and the other end of which is hinged to the outer diameter limiter 651;

[0091] a spring 654, one end of which is connected to the bearing surface and the other end of which is connected to the rotating rod 653;

[0092] Since the outer diameter limiter 651 is tilted toward the vertical winding mold 12 under the action of gravity and the stretching action of the spring 654, the outer diameter limiter 651 cannot conflict with the positive cake coil that has just been wound. Therefore, before use, the rotating rod 653 must first be opened in the direction away from the vertical winding mold 12 to loosen the outer diameter limiter 651 from the vertical winding mold 12. Then, the outer diameter limiter 651 is tilted toward the coil under the action of gravity and the stretching action of the spring 654, and then the outer diameter limiter 651 is pressed on the positive cake coil. In the process of winding the coil later, the outer diameter limiter will continue to rise, and the outer diameter limiter has the effect of pressing and leveling the coil. Moreover, since the outer diameter limiter assembly 65 of the present invention presses the coil and has the spring 654 for stretching, the outer diameter limiter assembly 65 of the present invention can be used for winding and leveling coils of different specifications and sizes.

[0093] Specifically, when the reverse pancake coil is wound upward from the positive pancake coil, the first, second, third, and fourth lifting structures drive the wire feed frame 23 and the outer diameter limiting assembly 65 to rise to the preset position for winding the reverse pancake coil. At this time, the arc portion 655 is higher than the uppermost positive pancake coil. In this way, when the reverse pancake coil is just started to be wound, its outermost coil is limited by the limiting component to prevent the outermost wire of the reverse pancake coil from falling into the wire pancake of the lower layer, thereby ensuring the smooth winding of the reverse pancake coil; and because the arc portion 655 is extended outward, the range for placing the wire is increased, which facilitates the winding of the reverse pancake coil.

[0094] When winding the positive cake coil upward from the negative cake coil, the first, second, third and fourth lifting structures drive the wire feeding frame 23 and the outer diameter limit assembly 65 to move to the preset position for winding the positive cake coil; at this time, although the height of the coil to be wound has increased, due to the change in the winding angle, the wire feeding frame 23 is changed from a downwardly inclined setting to a horizontal setting, and the wire feeding frame 23 needs to be lowered to align the height of the horizontally transported wire with the height of the coil to be wound. Since the outer diameter limit member 651 shares the first lifting structure with the wire feeding frame 23, the outer diameter limit member 651 also descends with the wire feeding frame 23. The height of the outer diameter limit member 651 after descending is lower than the height of the uppermost coil to clear the side space where the positive cake coil is to be wound, thereby avoiding the protrusion of the outer diameter limit member 651 and hindering the winding of the positive cake coil in the horizontal direction.

[0095] Furthermore, the outer diameter limiter 651 includes a plurality of longitudinally arranged rollers 656 and a rubber track 657 covering the plurality of rollers 656, which can reduce damage to the conductor. The side of the rubber track 657 facing the coil forms a flattening portion 652 and an arc portion 655.

[0096] It should be noted that the lifting drive member 41 of the bending device 4 can be but is not limited to a hydraulic cylinder; the radial driving element 24 can be but is not limited to a cylinder, and multiple cylinders are provided and a limit member is provided on the driving end of each cylinder to limit the stroke of the cylinder, so that the stroke of each cylinder is different to meet a variety of radial distance changes; the first, second, third and fourth lifting structures can be but are not limited to linear modules. Since the wire conveyor 23 and the rotating ring frame 63 share the first lifting structure 21, the operation of the third and fourth lifting structures needs to be consistent with the operation of the first lifting structure 21.

[0097] It should also be noted that the present invention can use an angle measuring rotary encoder and a length measuring encoder to measure the length of the wire and control the bending of the wire. Its working principle belongs to the existing technology. Please refer to the application number CN201110374465.X, entitled "Automatic Bending Method for Single-Wire Pancake Coil of Transformer". The present invention will not go into details about this.

[0098] The present invention also provides a pancake coil automatic winding method, which is applied to a pancake coil automatic winding device, and the method comprises the following steps:

[0099] S0, provide a wire reel 32 to store the wire, and insert the wire end into the middle guide wheel 33, the bending device and the electric roller pair in sequence, and finally connect it to the vertical winding mold 12;

[0100] S1. After completing step S0, the wire feeding frame 23 is horizontally arranged in the wire output direction under the action of the first lifting structure 21 and the second lifting structure 22, and is in a normal coil input state; the vertical winding mold 12 and the electric roller pair rotate forward, and the wire is wound on the vertical winding mold 12 into a normal coil under the rotation of the vertical winding mold 12;

[0101] S2. After completing step S1, when the bending device 4 detects that the length of the wire conveyed is just enough to wind one layer of wire coil, the vertical winding die 12 and the electric roller pair stop rotating, and the lifting drive member 41 of the bending device drives the bending movable head 42 and the bending fixed head 43 to close together, thereby bending the wire located between the bending movable head 42 and the bending fixed head 43;

[0102] S3. After completing step S2, the lifting drive member 41 is reset, driving the bending movable head 42 away from the bending fixed head 43;

[0103] S4. After completing step S3, the vertical winding die 12 and the electric roller pair rotate forward simultaneously; when the coil is just wound, the vertical winding die 12 and the electric roller pair stop rotating simultaneously, thereby completing the winding of the coil;

[0104] S5. After completing step S4, the wire feeding frame 23 is raised to a certain height under the action of the first lifting structure and the second lifting structure, and the wire output direction of the wire feeding frame 23 is tilted downward; the vertical winding mold 12 and the electric roller pair rotate forward at the same time, and the wire is reversely wound on the vertical winding mold 12 under the action of the vertical winding mold 12 and the electric roller pair; each time the wire is wound around once, the radial driving element 24 drives the wire feeding frame 23 to a certain distance close to the vertical winding mold 12;

[0105] S6. After completing step S5, when the bending device detects that the length of the wire is just enough to wind one layer of wire coil, the vertical winding die 12 and the electric roller pair stop rotating, and the lifting drive member 41 of the bending device drives the bending movable head 42 and the bending fixed head 43 to close together, thereby bending the wire located between the bending movable head and the bending fixed head;

[0106] S7. After completing step S6, the lifting drive member 41 is reset, driving the bending movable head away from the bending fixed head; the vertical winding mold 12 and the electric roller pair continue to rotate forward at the same time. When the bent part of the wire is just wound into an inverted pancake coil, the vertical winding mold 12 stops rotating and the electric roller pair flips over to tighten the inverted pancake coil so that each turn of the wire in the inverted pancake coil is close to each other without looseness or gaps.

[0107] S8. After completing step S7, the electric roller pair stops rotating, and the wire feeding frame 23 is moved to the next preset position under the action of the first lifting structure and the second lifting structure, so that the wire feeding frame 23 is set horizontally to prepare for the next winding of the positive coil, thereby cycling the winding action of the positive coil and the reverse coil.

[0108] S9. When it is detected that all coils are wound, the operation stops.

[0109] The present invention provides an automatic winding method for pancake coils, which adopts two lifting structures to change the wire feeding inclination angle and the wire feeding height of the conductor, and assists the vertical winding mold in winding by means of electric roller auxiliary wire feeding. During the winding process, a bending device is used to bend the connection between the positive pancake coil and the reverse pancake coil upward, and the reverse pancake coil is tightened after winding to achieve one-time winding of the positive pancake coil and the reverse pancake coil. The method has a high degree of automation and does not require the use of detachable auxiliary tooling.

[0110] Furthermore, during the coil winding process, the outer diameter limiter 651 simultaneously presses the outer periphery of the wound coil in the radial direction, thereby making the outer diameter of the coil uniform as a whole;

[0111] When a straight pancake coil needs to be wound, the outer diameter limiter 651 is set lower than the uppermost coil to free up the side space where the straight pancake coil is to be wound, thereby preventing the outer diameter limiter 651 from protruding and hindering the horizontal winding of the straight pancake coil.

[0112] When it is necessary to wind the inverted pancake coil, the outer diameter limiter 651 is set higher than the uppermost coil. When the inverted pancake coil is just started to be wound, the outermost coil is limited by the limiter to prevent the outermost wire of the inverted pancake coil from falling into the coil of the lower layer, thereby ensuring the smooth winding of the inverted pancake coil.

[0113] The present invention is not limited to the above-mentioned embodiments. If various changes or modifications of the present invention do not depart from the spirit and scope of the present invention, and if these changes and modifications fall within the scope of the claims of the present invention and equivalent technologies, the present invention is also intended to include these changes and modifications.

Claims

1. A pancake coil automatic winding device, characterized in that: include: A winding device, comprising a driving motor and a vertical winding die, wherein the driving motor is drivingly connected to the vertical winding die; A wire feeding device, comprising a first lifting structure, a second lifting structure and a wire feeding frame, wherein the wire feeding frame is rotatably mounted on the first lifting structure and the second lifting structure; After each layer of wire coils is wound, the first lifting structure and the second lifting structure jointly drive the wire feeding frame to rise and make the wire feeding frame in a positive coil feeding state or a reverse coil feeding state; When the line transmission rack is in a normal line-in state, the line-out direction of the line transmission rack is horizontally arranged; When the wire transmission rack is in the reversed wire feeding state, the wire output direction of the wire transmission rack is set obliquely downward; A radial driving element is installed on the wire feeding frame, and the wire feeding frame performs radial reciprocating motion relative to the vertical winding die under the action of the radial driving element; When the inverted pancake coil is wound, each time the conductor is wound around one circle, the radial driving element drives the wire conveying frame to approach the vertical winding mold by a certain distance.

2. The pancake coil automatic winding equipment according to claim 1 is characterized in that: A wire outlet guide wheel is provided on one side of the wire transmission frame close to the vertical winding mold; A wire reel is arranged on a side of the wire transmission frame away from the vertical winding mold; An intermediate guide wheel is arranged between the wire drum and the wire outlet guide wheel.

3. The automatic pancake coil winding equipment according to claim 2 is characterized in that: The outlet wire guide wheel is an electric roller pair, and the electric roller pair includes two electric rollers arranged in parallel; The forward rotation speed of the electric roller pair is adapted to the rotation speed of the vertical winding die; Each time after a layer of inverted pancake coil is wound, the vertical winding die stops rotating and the electric roller pair reverses.

4. The pancake coil automatic winding equipment according to claim 1 is characterized in that: The pancake coil automatic winding device also includes a bending device to bend the wire upward for transition between the positive pancake coil and the negative pancake coil; the bending device includes: A lifting drive member, which is fixed on the wire transmission rack; A bending movable head connected to the lifting drive member; A bending fixed head, which is arranged above the bending movable head; The movable bending head and the fixed bending head are respectively provided with opposite bending grooves. When the wire is fed from the wire feeding frame to the vertical winding die, the wire passes between the movable bending head and the fixed bending head.

5. The automatic pancake coil winding device according to claim 4 is characterized in that: The pancake coil automatic winding equipment also includes an insulation wrapping device, which is arranged on the wire transmission frame and located at the wire outlet side of the bending device.

6. The automatic pancake coil winding device according to claim 5, characterized in that: The insulation wrapping device comprises an insulation tape winding machine having a C-shaped winding area, wherein the C-shaped winding area is located outside the transmission frame, and the transported wires are inserted into the C-shaped winding area.

7. The automatic pancake coil winding equipment according to claim 1, characterized in that: The pancake coil automatic winding device also includes an outer diameter limiting device for flattening the coil, and the outer diameter limiting device includes: The third lifting structure and the fourth lifting structure are respectively and evenly distributed on the outer side of the vertical winding mold with the first lifting structure; A rotating ring frame, which is sleeved on the vertical winding mold and is connected to the first, third and fourth lifting structures and is arranged below the wire conveying frame, and a bearing is arranged on the annular surface of the rotating ring frame; A plurality of outer diameter limiting components, which are arranged on the bearing surface and evenly distributed circumferentially along the vertical winding die; When the coil is wound, the outer diameter limiting component is lifted and radially pressed on the coil under the joint action of the first, third and fourth lifting structures.

8. The automatic pancake coil winding equipment according to claim 7, characterized in that: The outer diameter limiting component comprises: The outer diameter limiter comprises a flattening portion that contacts the coil; the upper end of the flattening portion is provided with an arc portion extending outward; A rotating rod, one end of which is hinged to the bearing surface, and the other end of which is hinged to the outer diameter limiter; A spring has one end connected to the bearing surface and the other end connected to the rotating rod.

9. A method for automatically winding a pancake coil, characterized in that: Applied to automatic pancake coil winding equipment, the method comprises the following steps: S0, provide a wire reel to store the wire, and insert the wire ends of the wire into the middle guide wheel, the bending device and the electric roller pair in sequence, and finally connect them with the vertical winding mold; S1, after completing step S0, the wire delivery frame is horizontally arranged in the wire outlet direction under the action of the first lifting structure and the second lifting structure, and is in a positive coil input state; the vertical winding mold and the electric roller pair rotate forward, and the wire is wound into a positive coil on the vertical winding mold under the rotation of the vertical winding mold; S2. After completing step S1, when it is detected on the bending device that the length of the wire conveyed is just enough to wind a layer of wire coil, the vertical winding die and the electric roller pair stop rotating, and the lifting drive member of the bending device drives the bending movable head and the bending fixed head to close together, so as to bend the wire located between the bending movable head and the bending fixed head; S3, after completing step S2, the lifting drive member is reset to drive the bending movable head away from the bending fixed head; S4, after completing step S3, the vertical winding die and the electric roller pair rotate forward at the same time; when the coil is just wound, the vertical winding die and the electric roller pair stop rotating at the same time, thereby completing the winding of the coil; S5, after completing step S4, the wire transmission frame rises to a certain height under the action of the first lifting structure and the second lifting structure, and the wire output direction of the wire transmission frame is tilted downward; the vertical winding mold and the electric roller pair rotate forward at the same time, and the wire is reversely wound on the vertical winding mold under the action of the vertical winding mold and the electric roller pair; each time the wire is wound around, the radial driving element drives the wire transmission frame to approach the vertical winding mold by a certain distance; S6. After completing step S5, when it is detected on the bending device that the length of the wire is just enough to wind a layer of wire coil, the vertical winding die and the electric roller pair stop rotating, and the lifting drive member of the bending device drives the bending movable head and the bending fixed head to close together, so as to bend the wire located between the bending movable head and the bending fixed head; S7, after completing step S6, the lifting drive member is reset, driving the bending movable head away from the bending fixed head; the vertical winding die and the electric roller pair continue to rotate forward at the same time, and when the bending part of the wire is just wound into an inverted pancake coil, the vertical winding die stops rotating, and the electric roller pair flips over to tighten the inverted pancake coil; S8, after completing step S7, the electric roller pair stops rotating, and the wire feeding frame is moved to the next preset position under the action of the first lifting structure and the second lifting structure, and the wire feeding frame is set horizontally in the wire output direction, so as to prepare for the next winding of the positive coil, thereby cyclically winding the positive coil and the reverse coil; S9. When it is detected that all coils are wound, the operation stops.

10. The automatic winding method of pancake coil according to claim 9, characterized in that: During the coil winding process, an outer diameter limiter is used to radially press the outer circumference of the wound coil, thereby making the outer diameter of the coil flat as a whole; When a positive pancake coil needs to be wound, the outer diameter limiter is set lower than the uppermost coil; When it is necessary to wind the inverted pancake coil, the outer diameter limiter is arranged higher than the uppermost coil.

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