Device and method for winding annular core without using material storage box

Abstract

The present invention relates to a device and method for winding an annular core, which can be guided in an annular core holding element, wherein the wire includes a plurality of wire segments and does not require the use of a storage box. The device also includes: a substantially circular needle roller, which is rotatably mounted on a winding plane substantially parallel to the wire, and can be positioned relative to the annular core holding element so that the needle roller winds the wire segment located on the winding plane through and around the annular core, and the annular core is guided in the annular core holding element during operation. The needle roller also includes a deflection roller, which is rotatably mounted on the needle roller in a first recess on the winding plane and is arranged to wind the wire segment located on the winding plane through and around the annular core during operation. The needle roller also includes a baffle, which is arranged in a second recess adjacent to the first recess on the winding plane on the needle roller, and is designed to guide the wire to be wound between the winding plane and the storage plane through a guide groove during operation, and the storage plane is arranged substantially parallel to the winding plane. The device further comprises a plurality of storage elements arranged on the storage plane, the storage elements being mounted in a fixed and rotatable manner and being configured to store line segments located on the storage plane.

Description

Technical Field

[0001] The invention relates to a device and a method for winding an annular core with a wire material, which can be guided in an annular core holding element, the wire material comprising a plurality of wire segments, without using a material storage box. Background Art

[0002] For example, a device for winding annular cores is known from DE 10153896 A1, which has an annular storage device guided by an annular core opening, with elements for line guiding and line storage box devices. The shortcoming of this known device is that the annular storage box for storing and winding must be guided through the annular core, so that the storage box cannot be guided through annular cores of small diameters due to the space requirement of the storage box, or when winding thicker wire, the storage box cannot be fully wound.

[0003] For example, another annular core winding device is known from EP 2 953 149 B1, which has an annular core holding device and a wire guide without a magazine. A disadvantage of this known device is that the winding quality may be reduced due to the fact that the wire is occasionally not monitored or controlled during operation, and the accuracy of the wire layer on the annular core without bridging cannot always be guaranteed. Summary of the invention

[0004] Therefore, the object of the invention is to provide a kind of material storage box winding annular core device, and corresponding winding method, can realize the automatic winding of material storage box annular core without material storage box, especially relatively small annular core diameter and the very small annular core of diameter.In addition, this device is intended to design simple and firm, and has low production cost.Different from prior art, the winding without material storage box is understood to mean that the annular material storage box is not needed to be guided through the annular core opening.

[0005] To achieve this object, the invention provides a device having an annular core holding element for winding an annular core, which can be guided in the annular core holding element, using a wire comprising a plurality of wire segments, wherein the annular core holding element and the wire driven to wind the annular core are preferably aligned perpendicularly to each other. The device also includes at least one substantially circular needle roller, which is arranged in a winding plane substantially parallel to the wire, the needle roller being rotatably mounted and positionable relative to the annular core holding element so that the needle roller winds through the wire segment located in the winding plane and around the annular core, which is guided in the annular core holding element during operation. The needle roller also includes a deflection roller and a baffle, the deflection roller being rotatably mounted in a first recess in the winding plane at the needle roller and being arranged to wind the wire segment located in the winding plane through and around the annular core during operation, the baffle being arranged in a second recess in the winding plane on the needle roller, adjacent to the first recess, and being arranged to guide the wire to be wound during operation via a guide groove, which is between the winding plane and a storage plane arranged substantially parallel to the winding plane. The device further comprises a plurality of storage elements arranged in the storage plane, the storage elements being mounted in a fixed and rotatable manner and being arranged to store line segments located in the storage plane.

[0006] To solve this purpose, a method for winding an annular core is also proposed, which can be guided in an annular core holding element without a storage box, using a wire material including multiple wire segments. The method includes the rotation of a needle roller, which includes a baffle and a deflection roller, passing through the annular core, and also includes the following steps: guiding the wire segments of the wire material stored on several storage elements and located in the storage plane from the storage element arranged in the storage plane to the deflection roller via the guide groove of the baffle, the deflection roller being arranged in a winding plane arranged substantially parallel to the storage plane; guiding the wire segments located in the winding plane around the deflection roller and onto the annular core; winding the annular core with the wire segments located in the winding plane; and guiding any wire segments that are not wound and still exist in the winding plane back to the respective storage elements in the storage plane via the deflection roller through the guide groove.

[0007] According to the present invention, storage is performed by a storage element arranged in a storage plane, and the wire segments located in the storage plane are stored on the storage element. Since the wire of a predetermined length from the wire storage is wound on the annular core and stored on the storage element at the same time, the cycle time of the winding process is relatively reduced. Due to the use of a storage element that is not guided through the annular core during storage and winding, and in connection with this, the traditional storage box for storing wires is cancelled, so at the end of winding, only the wire segments present in the winding plane are guided through the annular core, so that even an annular core with a very small residual hole diameter (the inner diameter of the winding annular core with the wound wire layer at the end of winding) can be wound. In addition, due to this, compared with traditional annular core winding machines, an annular core with a smaller inner diameter or thicker wire can be wound.

[0008] Compared with traditional annular core (coil) winding device, this device has the annular material storage box guided by the annular core opening, and device design according to the present invention is simple, because can cancel the annular material storage box.Due to relatively simple design, this device is equally sturdy and has low production cost.Therefore, method according to the present invention allows to automatically wind under the situation that there is no material storage box, even has the annular core of small internal diameter or has the annular core of other core geometry, and these cores can not be wound with traditional annular core (coil) winding device with material storage box.

[0009] Compared to conventional toroidal core winding devices with multiple wire segments stored in the winding plane, the invention has a simple design, since no conveying rollers, wire guides and wire pullers are required. Due to the relatively simple design, the device is also robust and inexpensive to produce. Thus, the method according to the invention allows the automatic winding of even toroidal cores with small inner diameters or other core geometries without a storage box, which cannot be wound with conventional toroidal core winding devices with multiple wire segments stored in the winding plane.

[0010] According to one aspect of the invention, the interruption interrupts the basic circular shape of the needle roller in one area so that the annular core can be positioned on the circumference of the needle roller or the needle roller can be positioned in a position for winding the annular core, wherein the needle roller is arranged in such a way that it can rotate through the annular core. After the winding is completed, the needle roller can leave this position and the annular core can be removed from the annular core holding element. This allows for simplified winding, simple automation of the process and a reduction in the process time for winding the annular core.

[0011] According to another aspect of the invention, the needle roller comprises a toothed rim which is arranged in a drive plane substantially parallel to the winding plane and is arranged to drive the needle roller in rotation. The toothed rim comprises a tooth arrangement by means of which it is driven by an external drive unit. The rotational movement of the toothed rim is transmitted to the needle roller so that the annular core can be wound. This increases the mastery of the process and simplifies the operation of the device.

[0012] According to another aspect of the invention, the needle roller is arranged so that during operation, the needle roller simultaneously winds the wire segments located in the winding plane onto the wire segments in the storage plane and stores the wire segments in the storage plane onto a plurality of storage elements. Initially, wire is introduced into the device from the wire storage until a predetermined length of wire is introduced. The predetermined length of wire from the wire storage is simultaneously wound through and around the annular core and stored on the storage elements located in the storage plane. When the predetermined length of wire has been fed out of the wire storage device, the wire is separated from the wire storage device so that no more wire is fed out of the storage device and the wire segments located in the winding plane pass through and are wound around the annular core. As a result, the amount of remaining wire that cannot be wound onto the annular core is minimized and simple automation of the process becomes possible.

[0013] According to another aspect of the invention, the needle rollers are arranged so that the wire lying in the winding plane can be wound in the center of the toroidal core. As a result, the quality of the wound toroidal core is improved, since the wire winding is in each case wound perpendicularly to the toroidal core having a substantially circular geometry by the winding process. Among other things, this aspect provides more space inside the toroidal core during winding. This also allows a relative lateral movement between the toroidal core and the needle rollers, in order to, for example, move an toroidal core having a non-circular geometry into a central position relative to the needle rollers.

[0014] According to another aspect of the invention, the device further comprises at least one wire brake, wherein the at least one wire brake is arranged to brake the wire segments in the storage plane at intervals by pressing at least one element of the plurality of storage elements and to tension the wire during operation. As a result, the tensile load on the wire can be adjusted and the load on the wire can be kept constant, so that the risk of the wire tearing or being wound too loosely on the annular core can be reduced.

[0015] According to another aspect of the invention, a plurality of storage elements are arranged as rollers, which are arranged at intervals in interaction with at least one wire brake and are driven to rotate. In a preferred embodiment, the storage element is mounted on the side facing away from the needle roller and is closed by the surrounding area. In addition, in a preferred embodiment, a device is provided on the side of the storage element facing the needle roller, which device is used to prevent the wire segments present in the storage plane from falling out of the storage element undesirably during the winding process. These devices are preferably circumferential chamfered edges. In an area of ​​the circumferential path of the needle roller, the needle roller has passed the deflection roller within one rotation, the wire segments are present in the winding plane, and the wire segments present in the storage plane are driven by the roller in the direction of rotation of the needle roller and are not braked by at least one wire brake. In an area of ​​the circumferential path of the needle roller, the needle roller has not passed the deflection roller with the wire segments present in the winding plane in one rotation, and the wire segments present in the storage plane are not driven by the roller in the direction of rotation of the needle roller, but are braked by at least one wire brake. As a result, the load on the wire can be kept constant and the risk of tearing is reduced. Furthermore, this prevents the wire from loosely moving in the system during the winding process, thus improving the quality of the winding. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Exemplary embodiments of the present invention are described in more detail below with reference to the accompanying drawings. These show:

[0017] Figure 1 The figure shows a schematic side view of an embodiment of a device for winding annular cores without a magazine, wherein, for the sake of simplicity, the annular core holding element and the wire storage are not shown, among other elements.

[0018] Figure 2 The diagrammatic front view shows a section of an embodiment of a device for winding annular cores without a magazine, wherein, for the sake of simplicity, the annular core holding element and the wire storage are not shown, among other elements.

[0019] Figure 3 The diagrammatic side view shows a section of an embodiment of a device for winding annular cores without a magazine, wherein, for the sake of simplicity, the annular core holding element and the wire storage are not shown, among other elements.

[0020] Figure 4 The diagrammatic side view shows a section of an embodiment of a device for winding annular cores without a magazine, wherein, for the sake of simplicity, the annular core holding element and the wire storage are not shown, among other elements.

[0021] Figure 5A schematic side view of a part of an embodiment of a device for winding annular cores without a magazine, wherein, for the sake of simplicity, the annular core holding element and the wire storage are not shown, among other elements.

[0022] Figure 6 A flow chart of a method for winding annular cores without a storage box according to an embodiment of the present invention. DETAILED DESCRIPTION

[0023] according to Figures 1 to 3 , the storage box-free winding device 1000 for winding the annular core 2000 preferably includes an annular core holding element (not shown), and the annular core 2000 to be wound is kept in the annular core and is held and rotated in the holding element during winding. According to this embodiment, the annular core holding element is formed by three pressure rollers (not shown), which are preferably arranged at 120 ° angles to each other around the annular core 2000 in each case and press against the annular core 2000 from the outside, and therefore keep it in the desired position. At least one pressure roller drives the annular core 2000 at the same time, and therefore sets it to the desired rotation, so as to wind the winding at the distance interval desired from the annular core 2000.

[0024] Instead of a storage box, the device 1000 for winding an annular core 2000 without a storage box comprises a plurality of storage elements 1210, 1220, 1230, 1240, which are arranged in a storage box plane 4200, fixedly and rotatably mounted, and are arranged to store a line segment 3200 on the storage plane 4200. The rotation axis of the annular core 2000 is preferably substantially located in the winding plane 4100, and the rotation axes of the annular core 2000 and the storage elements 1210, 1220, 1230, 1240 are preferably substantially arranged perpendicularly to each other.

[0025] according to Figures 1 to 3 In the embodiment shown, the storage elements 1210, 1220, 1230, 1240 are evenly distributed along the circumferential path of the needle roller 1100. The wire segments 3200 located in the storage plane 4200 are stored on the storage elements 1210, 1220, 1230, 1240 and pulled out from these storage elements as needed during winding. In this case, the number of storage elements 1210, 1220, 1230, 1240 is not limited, but an embodiment with at least four storage elements 1210, 1220, 1230, 1240 is preferred.

[0026] For further winding, the annular core 2000 is wound by the needle roller 1100 and the deflection roller 1111 using the wire segment 3100 located in the winding plane 4100. Due to the rotation of the needle roller 1100 and the deflection roller 1111, the wire segment 3200 located in the storage plane 4200 guides the wire 3000 stored on the plurality of storage elements 1210, 1220, 1230, 1240 from the storage elements 1210, 1220, 1230, 1240 to the deflection roller 1111 via the guide groove 1121 of the baffle 1122. The wire segment 3100 located in the winding plane 4100 is then guided to the annular core 2000 around the deflection roller 1111 and wound around the annular core 2000. After the wire segments 3100 located in the winding plane 4100 are wound around the annular core 2000, the wire segments 3100 located in the winding plane 4100 and not yet wound are then guided back to the plurality of storage elements 1210, 1220, 1230, 1240 in the storage plane 4200 via the deflection roller 1111 through the guide groove 1121. As the winding of the wire 3000 on the annular core 2000 continues, the number of wires 3000 decreases, i.e. the wire segments 3100 located in the winding plane 4100 and the wire segments 3200 located in the storage plane 4200 are guided through the annular core 2000. As a result, in particular, the annular core 2000 can also be wound, and its residual aperture (the inner diameter of the wound annular core 2000 on which the wire layer is wound as the winding progresses) becomes smaller during the winding process.

[0027] The unwound wire segment 3200 located in the storage plane 4200 is braked at intervals by at least one wire brake 1510, 1520, 1530, 1540 by pressing against at least one of the plurality of storage elements 1210, 1220, 1230, 1240, and is thus kept taut during operation. According to one embodiment, the plurality of storage elements 1210, 1220, 1230, 1240 are configured as rollers, which are driven to rotate at intervals in interaction with at least one wire brake 1510, 1520, 1530, 1540. In a preferred embodiment, the storage elements 1210, 1220, 1230, 1240 are stored on the side facing away from the needle roller 1100 and are surrounded by a surrounding area. Furthermore, in a preferred embodiment, devices are provided on the side of the storage elements 1210, 1220, 1230, 1240 facing the needle roller 1100, which are used to prevent the wire segments 3200 present in the storage plane 4200 from undesirably falling off from the storage elements 1210, 1220, 1230, 1240 during the winding process. These devices are preferably such as Figure 2 The circumferential chamfered edges 1211, 1221, 1231, 1241 are shown. Figure 3As shown, in one area of ​​the circumferential path of the needle roller 1100, the needle roller 1100 has passed the deflection roller 1111 within one rotation, and the wire segment 3100 is present in the winding plane 4100, and the wire segment 3200 present in the storage plane 4200 is driven by the roller in the rotation direction of the needle roller 1100 and braked by at least one wire brake 1510, 1520, 1530, 1540. In one area of ​​the circumferential path of the needle roller 1100, the needle roller 1100 has not passed the deflection roller 1111 with the wire segment 3100 present in the winding plane 4100 within one rotation, and the wire segment 3200 present in the storage plane 4200 is not driven by the roller in the rotation direction of the needle roller 1100 and braked by at least one wire brake 1510, 1520, 1530, 1540. Therefore, the load on the wire 3000 can be kept constant and the risk of tearing is reduced. Furthermore, this also prevents the wire 3000 from moving loosely in the system during winding, thereby improving the quality of the winding.

[0028] According to one embodiment, reference may be made to Figures 4 to 6 The method 6000 for winding the annular core 2000 without using a storage box is described as follows. The annular core 2000 is held in the annular core holding element and rotated during winding. Next, the wire end 3300 is guided out of the wire storage, around the turning roller 1111, and passed through the annular core 2000, as shown in FIG. Figure 4 and 5 As shown. The wire end 3300 guided through the annular core 2000 is fixed (shown as a cross), and the needle roller 1100 winds the first winding around the annular core 2000. Now, the first winding fixes the wire 3000 during further winding, and the needle roller 1100 can wind more turns without external fixing. Subsequently, a predetermined length of wire 3000 is brought into the device 1000 from the wire storage. Thus, as Figure 5 As shown, a predetermined length of wire 3000 from the wire storage is simultaneously wound through and around the annular core 2000 and stored on the storage elements 1210, 1220, 1230, 1240. When the predetermined length of wire 3000 is stored on the storage elements 1210, 1220, 1230, 1240 located in the storage plane 4200, the wire 3000 is completely brought into the device 1000. When the predetermined length of wire 3000 has been guided out of the wire storage and stored on the storage elements 1210, 1220, 1230, 1240, the wire 3000 is separated from the wire storage and thus no longer guided from the wire storage, and the wire segment 3100 located in the winding plane 4100 is further wound through and around the annular core 2000, as shown. Figure 3As a result, any amount of remaining wire that cannot be wound onto the annular core 2000 is minimized, and thus automatic winding of the annular core 2000 without a storage box is possible.

[0029] Figure 6 A flow chart 6000 of a method for winding an annular core without using a storage box according to one embodiment of the present invention is shown. According to step 6100, during the winding process, a line segment 3200 of a line stored on a plurality of storage elements 1210, 1220, 1230, 1240 located in a storage plane 4200 is guided from the storage elements 1210, 1220, 1230, 1240 via a guide groove 1121 of a baffle 1122 to a deflection roller 1111. In this case, the deflection roller 1111 is preferably arranged in the winding plane 4100, substantially parallel to the storage plane 4200. According to another step 6200, the line segment 3100 located in the winding plane 4100 is guided around the deflection roller 1111 to the annular core 2000. According to a third step 6300, the annular core 2000 is wound with the line segment 3100 located in the winding plane 4100. In this case, the annular core 2000 is held by the annular core holding element and rotates during the winding process. According to another step 6400, the unwound wire segment 3100 located in the winding plane 4100 is then guided back to the plurality of storage elements 1210, 1220, 1230, 1240 in the storage plane 4200 via the guide groove 1121 via the deflection roller 1111.

[0030] In the sense of the present invention, the term annular core also comprises tubular core or has the core of special opening geometry, and especially refers to the less annular core with internal diameter or has the core of inclined opening geometry, and tubular core, due to its size reason, can't use traditional annular core winding device to wind, because due to the required space of storage box, storage box can't be guided by the annular core opening.Yet the embodiment described here is also very suitable for winding other annular cores or has the core of other openings, and has the core of larger internal diameter, and allows simple and easy winding.

[0031] In the meaning of the present invention, the term "wire" also includes all other materials which are used in a reasonable manner according to the invention to be wound around a toroidal core or the like.

[0032] A person skilled in the art may derive further advantageous embodiments and derivations from the exemplary embodiments described herein and understand them to belong to the present invention.

Claims

1. A device for winding a toroidal core with a wire having an toroidal core holding element, wherein the toroidal core can be guided in the toroidal core holding element, wherein the wire comprises a plurality of wire segments, and wherein the device further comprises include: a circular needle roller arranged parallel to the wire and mounted to be rotatably movable, and the needle roller can be positioned relative to the annular core holding element so that the needle roller during operation passes the wire segment located in the winding plane through and around the annular core guided in the annular core holding element, wherein the needle roller further comprises: a deflection roller rotatably mounted in a first recess in the winding plane at the needle roller and arranged to pass a wire segment located in the winding plane through and around the annular core during operation; and a baffle, arranged in a second recess in the winding plane, adjacent to the first recess at the needle roller, and arranged to guide the wire to be wound between the winding plane and a storage plane arranged parallel to the winding plane via the guide groove during operation, And the device also includes: A plurality of storage elements are arranged in the storage plane, the storage elements being mounted in a fixed and rotatable manner and being arranged to store line segments located in the storage plane.

2. The device according to claim 1, in, An interruption interrupts the circular shape of the needle roller in one area so that the needle roller can be positioned in a position provided for winding of the annular core, and wherein the needle roller is arranged so that it can rotate through the annular core.

3. The device according to claim 1, in, The needle roller comprises a toothed rim which is arranged in a driving plane arranged parallel to the winding plane and is arranged to drive the needle roller in rotation.

4. The device according to claim 1, in, The needle roller is arranged to wind a wire segment located in the winding plane during operation while passing through and around an annular core guided in the annular core holding element and to store the wire segment located in the storage plane on the plurality of storage elements.

5. The device according to claim 1, in, The deflection roller is arranged to pass a line segment located in the winding plane centrally through and around the annular core.

6. The device according to claim 1, further comprising at least one wire brake, wherein the at least one wire brake is configured to brake a wire segment located in the storage plane by pressing at least one of the plurality of storage elements at intervals and to keep the wire taut during operation.

7. The device according to claim 6, in, The plurality of storage elements are rollers that are arranged at intervals and driven to rotate in interaction with the at least one wire brake.

8. A method for winding a toroidal core with a wire comprising a plurality of wire segments, the toroidal core being capable of being guided in an toroidal core holding element, in, The method comprises rotating a needle roller comprising a baffle and a deflection roller through the annular core, the method comprising the steps of: a. guiding the wire segments of the wire stored in the plurality of storage elements in the storage plane from the storage element arranged in the storage plane via the guide groove of the baffle to the deflection roller, the deflection roller being arranged in a winding plane arranged parallel to the storage plane, b. guiding the line segment located in the winding plane around the turning roller to the annular core; c. winding the annular core with a line segment located in the winding plane; and d. The wire segments which have not yet been wound are guided via the deflection rollers in the winding plane back through the guide grooves and onto a plurality of storage elements in the storage plane.

9. The method for winding a toroidal core according to claim 8, in, During operation, the annular core guided in the annular core holding element rotates perpendicularly to the rotation of the needle roller.

10. The method for winding a toroidal core according to claim 8, in, The wire on the storage element is tensioned at intervals by at least one wire brake.

11. The method for winding a toroidal core according to claim 8, in, The method is performed by using the device for winding annular cores according to any one of claims 1 to 7.

12. The method for winding a toroidal core according to claim 8, in, At the start of the method, wire segments located in the winding plane are wound simultaneously through and around the annular core, and the required amount of wire is stored on a plurality of storage elements in the storage plane.

13. The method for winding a toroidal core according to claim 8, in, Steps a to d are repeated to wind a desired number of wire windings onto the annular core.

Images