Continuous pancake coil winding method and device

Abstract

The present invention provides a continuous pancake coil winding method and device, which divides a single coil into a positive pancake coil winding segment and a reverse pancake coil winding segment; with the boundary between the positive pancake coil winding segment and the reverse pancake coil winding segment as the starting point, after the reverse pancake coil winding segment is bent to one side of the positive pancake coil winding segment, the positive pancake coil winding segment is wound on the winding die at a speed A, and the reverse pancake coil winding segment is reversely wound on the winding die at a speed greater than A. In order to realize the simultaneous winding of the positive pancake and the reverse pancake, a moving spindle box and a pre-winding disk are provided, and the wire of the reverse pancake coil is wound on the pre-winding disk, and the moving 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, so that the wire is reversely wound on the winding die, and the simultaneous and one-time winding of the positive pancake and the reverse pancake of the double pancake coil is realized continuously and efficiently.

Description

Technical Field

[0001] The present invention relates to the technical field of transformer product manufacturing, and more specifically, to a method and device for winding a continuous pancake coil. Background Art

[0002] The circuit part of the transformer is the winding, which is wound by copper wire or aluminum wire with high conductivity. The winding should have sufficient insulation strength, mechanical strength and heat resistance. Windings are usually divided into two types: layer type and pancake type. The turns of the winding are arranged in sequence along its axial direction and wound continuously, which is called layer winding. The turns of the winding are continuously wound along its radial direction to form a pancake (segment), and then the winding composed of many pancakes arranged along the axial direction is called pancake winding, which includes continuous type, inserted capacitor type and tangled type.

[0003] The coils of the continuous pancake winding are divided into positive and negative coils. When the pancake coil is wound, all odd-numbered coils are negative coils, and all even-numbered coils are positive coils. When the coil is wound by a winding machine, due to the different winding directions of the positive and negative coils, the prior art cannot directly complete the winding of a double coil including positive and negative coils by a winding machine.

[0004] The application number is CN202020967811.X, and the patent name is a utility model patent for a device for reverse winding of continuous windings. Its background technology points out that for horizontal winding machines, 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. It is necessary to first wind a temporary wire cake (temporary positive cake), and then turn the temporary wire cake (positive cake) 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, but because the winding machine is placed vertically, the reverse cake cannot be wound directly, and the winding of the reverse cake must be completed through the cooperation of auxiliary tooling. This patent designs a wire turning plate as an auxiliary tooling to wind the reverse cake.

[0005] The Chinese invention patent with application number CN201810650919.3 and patent name "Method for Winding Double Pancake Coils at the Input End of Rectifier Transformer" discloses a method for winding double pancake coils, which divides a single coil raw material into a positive pancake coil winding segment and a negative pancake coil winding segment, and wraps insulating material at a position adjacent to the positive pancake coil winding segment and the negative pancake coil winding segment; fixes the negative pancake coil winding segment, takes the end adjacent to the positive pancake coil winding segment and the insulating material as the winding starting end, and uses a winding device to wind the positive pancake coil winding segment on a winding mold circle by circle, thereby winding the positive pancake coil winding segment into a first pancake coil; flips the first pancake coil horizontally 180° and then fixes it, takes the end adjacent to the negative pancake coil winding segment and the insulating material as the winding starting end, and uses a winding device to wind the negative pancake coil winding segment on a winding mold circle by circle, thereby winding the negative pancake coil winding segment into a second pancake coil. This method does not require turning the wire or using turning tools, and can further complete the winding of positive and negative coils on the same winding die. However, during the winding process, it is necessary to stop halfway and turn the wound positive coil 180°, which reduces production efficiency.

[0006] The prior art also has two coils in the same direction wound by a winding machine, then the end of the first coil is the beginning of the second coil, that is, the end of the first coil is connected to the beginning of the second coil, the connection between the two coils is cut with a saw, the sawn part is polished flat, the second coil is flipped 180°, and the beginning of the first coil is welded to the beginning of the second coil, thereby forming a double-pancake coil with a positive pancake and a negative pancake. However, in this way, when the coil material is a metal tubular structure such as a copper tube and an aluminum tube, water must be added to these hollow tubular structures to play a heat dissipation role. When the positive pancake and the negative pancake are connected by welding, it is necessary to ensure that there is no leakage, otherwise the cooling water will flow out of the weld, causing serious quality problems in the winding. Summary of the invention

[0007] The technical problem to be solved by the present invention is to provide a continuous pancake coil winding method. When winding a double-pancake coil, the method does not need to stop the winding machine during the whole process and does not need to use tooling, and can continuously complete the one-time winding of the positive and negative pancakes of the double-pancake coil.

[0008] A continuous pancake coil winding method is provided, wherein a single coil is divided into a positive pancake coil winding segment and a reverse pancake coil winding segment; taking the boundary between the positive pancake coil winding segment and the reverse pancake coil winding segment as a starting point, the reverse pancake coil winding segment is bent to one side of the positive pancake coil winding segment, the positive pancake coil winding segment is wound on a winding die at a speed A, and the reverse pancake coil winding segment is wound on the winding die in the opposite direction at a speed greater than the speed A, thereby completing the winding of the positive pancake and the reverse pancake.

[0009] For example, the positive pancake coil winding segment rotates clockwise at speed A, and at the same time, the reverse pancake coil winding segment rotates counterclockwise in the opposite direction at a speed greater than speed A. The first speed is offset by the winding speed of the positive pancake coil winding segment, and the remaining speed is used for winding in the counterclockwise direction, thereby achieving simultaneous winding of the positive pancake and the reverse pancake. The length of the positive pancake coil winding segment and the reverse pancake coil winding segment is greater than or equal to the length of the wire of one coil (positive pancake or reverse pancake). Preferably, the length of the positive pancake coil winding segment and the reverse pancake coil winding segment is equal to the length of the wire of one coil.

[0010] Preferably, the inverted pancake coil winding segments are reversely wound on the winding mold at twice the speed A.

[0011] For example, the winding segment of the positive disk coil rotates clockwise at speed A, and at the same time, the winding segment of the reverse disk coil rotates counterclockwise at twice the speed A. The first speed cancels out the winding speed of the positive disk coil winding segment, and the remaining speed is used for winding in the counterclockwise direction, thereby completing the one-time winding of the positive disk and the reverse disk coil of the double disk coil.

[0012] On the other hand, since the shape of the double-pancake coil is a racetrack shape, a circle, etc. When the double-pancake coil is a racetrack shape, that is, the winding part of the winding mold is also a racetrack shape, the winding speed of the positive and negative coils is consistent, so that the positive and negative coils can be wound on the same racetrack winding mold at the same time.

[0013] The present invention also provides a device for implementing the above-mentioned continuous pancake coil winding method, comprising a pay-off mechanism, a fixed spindle box and a winding die, the winding die is installed on the fixed spindle box, the fixed spindle box drives the winding die to rotate to wind the wire on the pay-off mechanism onto the winding die; it also includes a moving spindle box and a pre-winding disk, the moving spindle box drives the pre-winding disk to rotate around the winding die; the winding die is located between the fixed spindle box and the moving spindle box, a positive pancake coil winding segment is wound on the pay-off mechanism, and a reverse pancake coil winding segment is wound on the pre-winding disk; the winding die and the pre-winding disk rotate coaxially and in the same direction, and the pre-winding disk rotation speed is greater than the winding die rotation speed, thereby achieving the positive pancake coil winding segment being wound on the winding die at a speed A, and the reverse pancake coil winding segment being wound on the winding die in the opposite direction at a speed greater than A.

[0014] It should be noted that the present invention has the following: the rotation direction of the pre-winding disk is the same as the rotation direction of the winding die, but the winding direction is opposite. The winding die pulls the positive cake coil winding segment to be wound on the winding die. The positive cake coil winding segment is passively wound on the winding die. If the winding die rotates clockwise, the passive positive cake coil winding segment is counterclockwise wound on the winding die. The pre-winding disk actively winds the reverse cake coil winding segment on the winding die. The direction of the pre-winding disk is the winding direction of the reverse cake coil winding segment, which is also clockwise. In summary, although the rotation direction of the winding die is the same as that of the pre-winding disk, the winding direction is opposite. Thus, the above-mentioned is achieved: the positive cake coil winding segment is wound on the winding die at a speed A, and the reverse cake coil winding segment is wound on the winding die in the opposite direction at a speed greater than A, thereby completing the winding of the positive cake and the reverse cake.

[0015] Before winding begins, the boundary between the positive coil winding segment and the reverse coil winding segment is used as the starting point. After the reverse coil winding segment is bent to one side of the positive coil winding segment, the positive coil winding segment and the reverse coil winding segment are placed side by side on the winding mold.

[0016] The present invention can simultaneously wind the positive and negative coils without using tooling for flanging, and the positive and negative coils of the double coil are originally a complete wire, so the present invention does not need to manually saw off the reverse side and then weld.

[0017] Furthermore, the movable spindle box includes a driving device 1 and a turntable 1, the driving device 1 drives the turntable 1 to rotate, the rotation axis of the turntable 1 coincides with the winding mold, and the pre-winding disk is installed at a position of the turntable 1 close to the outer edge of the turntable 1.

[0018] The relationship between the winding die and the pre-winding disk is like the relationship between the earth and the moon. The winding die itself is rotating, and the pre-winding disk rotates around the rotating winding die. The pre-winding disk cannot interfere with the rotation of the winding die when rotating, so the rotation radius is larger. The turntable 1 and the winding die rotate on the same axis, so the pre-winding disk is set at a position close to the outer edge of the turntable 1.

[0019] According to the present invention, if the rotation speeds of turntable one and the winding die are equal and the directions are the same, the positive disk coil winding segment can be smoothly wound on the winding die; since the speeds of turntable one and the winding die are equal, the reverse disk coil winding segment will not be wound on the winding die, so the first times rotation speed of turntable one and the rotation speed of turntable one cancel each other out, and only when the speed is greater than one times can the reverse disk coil winding segment be wound on the winding die.

[0020] Furthermore, the rotation speed of the turntable 1 is twice the rotation speed of the winding mold. When the rotation speed of the turntable 1 is twice the rotation speed of the winding mold, the winding of the positive coil and the negative coil can be completed at the same time. In particular, when the double coil is a runway type, that is, the winding part of the winding mold is also a runway type, the winding speeds of the positive coil and the negative coil are consistent, so that the positive coil and the negative coil can be wound on the same winding mold at the same time. Since the runway-type double coil has four straight edges, if the winding speeds of the positive coil and the negative coil are inconsistent, they cannot be wound on the winding mold at the same time, and can only be wound separately.

[0021] Furthermore, the fixed spindle box includes a turntable 2 and a driving device 2, and the turntable 2 is coaxial with the winding die; the driving device 2 drives the winding die to rotate; the turntable 1 and the turntable 2 are respectively fixed with a pressure wheel device, and the turntable 1 and the turntable 2 are collectively referred to as turntables; the pressure wheel device includes a pressure wheel and a mounting seat, and the pressure wheel is mounted on the turntable through the mounting seat, and the pressure wheel presses on the wire on the winding die; the mounting seat includes a compression device and a pressure wheel connecting structure, one end of the compression device is fixed to the turntable, and the other end is connected to the pressure wheel connecting structure, and a pressure wheel is fixed on the pressure wheel connecting structure; when the pressure wheel rises and falls, the compression device is compressed and reset accordingly.

[0022] Preferably, the compression means is a spring.

[0023] The pressure wheel applies pressure to the wire to prevent the wound wire from loosening. The expansion and contraction of the compression device causes the pressure wheel to move up and down as the coil rotates or rises. Since the first turntable is rotating, the pressure wheel on the first turntable rotates with the first turntable during winding; when the second turntable is stationary, the pressure wheel on the second turntable is fixed.

[0024] Furthermore, before winding, the pressing wheel presses on the tangent point where the wire enters the winding die.

[0025] Furthermore, a fixed block is provided on the turntable at one end where the compression device is connected to the pressure wheel connecting structure, and an inner hole is opened in the fixed block. The pressure wheel connecting structure includes a guide rod 1, which passes through the inner hole of the fixed block and is connected to the end of the compression device. When the compression device is compressed and reset, the guide rod 1 moves up and down along the inner hole of the fixed block.

[0026] Furthermore, the mounting seat also includes a guide rail, a slide, a drive device and a sensor, and the compression device is fixed to the turntable through the guide rail and the slide; the guide rail is installed on the turntable, and the slide is located on the guide rail; the drive device drives the slide to move up and down along the guide rail; after the compression device is compressed, the sensor receives a signal, and the drive device drives the slide to move up and down until the compression amount of the compression device reaches the set value, and the signal of the sensor disappears.

[0027] When the double-pancake coil is a runway type, the corresponding winding part of the winding mold is also a runway type, so when rotating, the pressure wheel fluctuates greatly; on the other hand, when the double-pancake coil is wound, the wires are stacked layer by layer, which will also cause the pressure wheel to rise, but relatively speaking, the fluctuation of the pressure wheel caused by rotation is much larger. The pressure of the pressure wheel on the wire at the highest point and the lowest point is very different, so the guide rail, slide, drive device and sensor are set to raise or lower the pressure wheel and compression device as a whole, keep the pressure of the pressure wheel on the wire fluctuating within a certain range, and avoid excessive or insufficient clamping force due to the shape change of the double-pancake coil. The compression of the pressure wheel spring is transmitted to the control device by the sensor.

[0028] Furthermore, the sensor is a proximity switch.

[0029] Furthermore, the driving device three is a motor and a screw-nut pair, the motor drives the screw to rotate, the slide is fixed to the nut, and the screw drives the slide to move up and down along a straight line.

[0030] Furthermore, the fixed spindle box also includes a driving device four, which drives the turntable two to rotate. The turntable two is also fixed with a push plate and a driving device five. The driving device five drives the push plate to move to contact the wire and apply pressure to the wire; the driving device five pushes the push plate to move closer to or away from the coil.

[0031] The present invention is also provided with a push plate, which also applies pressure to the wire so that the wire is well shaped around the winding die. When winding begins, the push plate and the pressure wheel are pressed on the wire at the same time, wherein the push plate is fixed on the second turntable. To ensure smooth winding and stable winding, the push plate must rotate with the winding die at a certain angle, so a driving device 4 is provided to drive the second turntable to rotate, so that the push plate installed on the second turntable can rotate with the winding die, and in this case, the rotation speeds of the second turntable and the winding die are equal.

[0032] Furthermore, guide plates are fixed on both sides of the push plate, and the guide plates are vertically installed on turntable 2. The guide plates serve as moving guides for the push plate. The push plate includes push plate 1 and push plate 2 arranged in parallel. L-shaped guide rails are respectively provided on the guide plates on both sides, and the push plate approaches or moves away from the double-pancake coil along the L-shaped guide rails; push plate 1 is connected to the output end of the driving device 5, and push plate 2 is movably connected to push plate 1 in a direction perpendicular to turntable 2; one end of the L-shaped guide rail is perpendicular to the coil, called a vertical guide rail; the other end is in an inclined state, called an inclined guide rail, and the inclined guide rail is inclined toward the direction of turntable 2.

[0033] The push plate action principle: the driving device 5 pushes the push plate 1 to move along the inclined guide rail, and the push plate 2 gradually extends from the guide plate along the inclined guide rail. After entering the vertical guide rail, the push plate 1 and the push plate 2 move relative to each other, and the push plate 2 further extends from the guide plate to apply pressure to the double pancake coil; the width of the extended push plate 2 is greater than or equal to the width of the double pancake coil. The driving device 5 contracts, and the push plate 2 moves away from the double pancake coil along the L-shaped guide rail, so that the push plate 2 retracts into the guide plate.

[0034] The setting of the push plate structure can avoid interference between the push plate and the tangent direction of the wire. When the push plate is extended and retracted, the trajectory is a curve bent in the second direction of the turntable and will not scratch the wire.

[0035] Furthermore, the position difference between the push plate and the pressure wheel is 90 to 180 degrees.

[0036] Especially for the runway type double pancake coil, there are four straight edges. Before winding, the pressure wheel is located directly above, that is, in the middle of a straight edge. The push plate is installed on the second turntable. The position of the push plate and the pressure wheel is 90 to 180 degrees apart. In short, it is in contact with the other three straight edges. After the push plate follows the winding die for a certain angle, such as 90 degrees, the push plate retracts, and the turntable 2 stops rotating, and the push plate stops following. After that, the winding die stops every 90 degrees, and the push plate extends out to press a straight edge of the double pancake coil.

[0037] Because the push plate and the pressing wheel of the positive coil are fixed on the turntable 2, there will be no interference between the push plate and the pressing wheel on the turntable 2. The pressing wheel on the turntable 1 rotates with the turntable 1, the winding die pauses, the pressing plate presses the coil, and the pressing plate is retracted immediately after pressing. During the rotation of the turntable 1, there will be no interference between the pressing wheel and the pressing plate.

[0038] Furthermore, the pressure wheel connection structure on turntable one and turntable two includes a connecting seat and a driving device six; the driving device six is ​​fixed to the turntable, the output end of the driving device six is ​​perpendicular to the turntable, the output end of the driving device six is ​​connected to the pressure wheel, and the driving pressure wheel extends from the turntable and resets.

[0039] Furthermore, the positions of the pressure wheel and the push plate on the second turntable are 90 degrees apart. This is because, when winding begins, the pressure wheel on the first turntable and the pressure wheel on the second turntable are both directly above the winding die, in the same position, and the two pressure wheels press the wires of their respective coils; the second turntable drives the pressure wheel and the push plate on it to rotate with the winding die. If the pressure plate rotates 180 degrees and the speed of the first turntable is twice the speed of the winding die, then the first turntable will rotate 360 ​​degrees, and the pressure wheel of the first turntable will collide with the push plate, and the pressure wheel on the first turntable will retract. Therefore, in order to avoid this unnecessary retraction, the positions of the pressure wheel and the push plate are 90 degrees apart.

[0040] Furthermore, the turntable 2 uses a circular drag chain for routing. The routing of the turntable 2 can also use electrical slip rings, but the use of electrical slip rings requires some structural design, making the overall structure more complicated. Although the routing of the circular drag chain is affected by the length of the circular drag chain and the rotation angle cannot be too large, in fact, the turntable 2 only needs 90 to 180 degrees to follow the routing. Therefore, it is preferred to use a circular drag chain for routing, which makes the overall structure simpler and can also meet the needs of actual applications.

[0041] The pressing wheel connection structure also includes a guide rod 2, which passes through the connecting seat and is fixed to the pressing wheel to guide the extension and reset of the pressing wheel.

[0042] Furthermore, the driving device five and the driving device six are cylinders.

[0043] Furthermore, the driving device 5 is fixed to the turntable 1 through a bracket, and guide plates are also fixed on both sides of the push plate to guide the movement of the push plate.

[0044] Furthermore, a wire wheel is also provided on the wire-releasing mechanism, and the winding segment of the positive disk coil passes through the wire wheel, and the wire wheel guides the winding segment of the positive disk coil.

[0045] Furthermore, a linear track is also provided on the wire-releasing mechanism, and the wire wheel moves up and down along the linear track.

[0046] Furthermore, a leveling and straightening mechanism is provided between the wire-releasing mechanism and the winding die for leveling and straightening the wire.

[0047] The winding mold is equivalent to the earth, which rotates on its own, and the pre-winding disk is equivalent to the moon, which rotates and revolves around the winding mold. The pre-winding disk speed mentioned in this application refers to the pre-winding disk revolution speed, and the pre-winding disk rotation direction refers to the revolution direction.

[0048] The present invention has the following beneficial effects compared with the prior art:

[0049] The present invention first provides a method for winding a continuous pancake coil. The prior art cannot wind a double pancake coil continuously and in one go. The present invention divides a whole wire of the double pancake coil into two parts, one part is used for winding a positive pancake, and the other part is used for winding a reverse pancake. The two parts are wound in opposite directions, and the reverse pancake winding speed is greater than the positive pancake winding speed. The winding speed is used to realize continuous and one-time winding of the double pancake coil.

[0050] The present invention also provides a continuous pancake coil winding device. In order to realize the simultaneous winding of the positive pancake and the reverse pancake, a movable main spindle box and a pre-winding disk are provided. The conductive wire of the reverse pancake coil is wound on the pre-winding disk. The movable main 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 reversely winding the conductive wire on the winding die, thereby realizing the simultaneous and one-time winding of the positive pancake and the reverse pancake of the double-pancake coil continuously and efficiently. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] The drawings constituting a part of the present application are used to provide a further understanding of the present invention. 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:

[0052] Figure 1 It is a schematic diagram of the double pancake coil structure.

[0053] Figure 2 yes Figure 1 Cross-sectional view in CC direction.

[0054] Figure 3 It is a schematic diagram of the structure of the winding device of the continuous pancake coil (stereoscopic diagram from the left side).

[0055] Figure 4 It is a schematic diagram of the structure of the winding device of the continuous pancake coil (stereoscopic diagram from the right view).

[0056] Figure 5 This is a schematic diagram of the structure of the winding device for the continuous pancake coil (right view).

[0057] Figure 6 It is a schematic diagram of the structure of the fixed spindle box and the movable spindle box.

[0058] Figure 7 It is a partial schematic diagram of the structure of the turntable and the pressure wheel device.

[0059] Figure 8 It is a schematic diagram of the turntable, winding die, pressure wheel device and push plate structure.

[0060] Fig. 9 It is a schematic diagram of the push plate structure.

[0061] Positive pancake coil -1a, negative pancake coil -1b, bending section -2, pay-off mechanism -3, wire pulley -31, fixed spindle box -4, turntable two -41, winding mold -5, movable spindle box -6, turntable one -61, counterweight block -62, pre-winding disk -7, pressure wheel device -8, pressure wheel -81, spring -82, guide rail -83, slide seat -84, proximity switch -85, fixed block -86, guide rod one -87, motor -88, screw rod -89, connecting seat -90, drive device six -91, guide rod two -92, push plate mechanism -10, push plate -101, push plate one -101a, push plate two -101b, drive device five -102, guide plate -103, L-shaped guide rail -104, guide strip -105, guide groove -106. DETAILED DESCRIPTION

[0062] The embodiments of the present invention are described in detail below with reference to the accompanying drawings, but the present invention can be implemented in many different ways as defined and covered by the claims.

[0063] Example 1

[0064] like Figure 1 As shown, it is a double pancake coil. Although the double pancake coil is composed of two layers of coils, the two layers of coils are required to be a complete coil, and the winding directions of the two layers of coils are opposite, one positive pancake coil 1a and one negative pancake coil 1b. The prior art cannot wind the double pancake coil continuously and in one go. The present invention creatively utilizes the winding speed to achieve continuous and one-time winding of the double pancake coil.

[0065] A method for winding a continuous pancake coil is as follows:

[0066] S1: Divide a single coil into a positive coil winding segment and a negative coil winding segment;

[0067] S2: Take the boundary between the positive coil winding segment and the reverse coil winding segment as the starting point, and bend the reverse coil winding segment to one side of the positive coil winding segment, such as Figure 2 As shown, 2 is a bending section;

[0068] S3: The winding segments of the positive coil are wound on the winding die at a speed A, and the winding segments of the negative coil are wound on the winding die in the opposite direction at twice the speed A, thereby completing the winding of the positive coil and the negative coil at the same time.

[0069] It should be noted that the length of the positive coil winding segment is equal to the length of a positive coil, and the length of the reverse coil winding segment is equal to the length of a reverse coil. Both the positive coil winding segment and the reverse coil winding segment come from the winding drum on the winding machine's pay-off mechanism. Before winding, a section of wire is pulled out from the winding drum, and the length of the pulled wire is the length of the reverse coil winding segment.

[0070] Example 2

[0071] This embodiment provides a continuous pancake coil winding device for implementing the method described in Embodiment 1, which is used to wind a continuous pancake coil. Figure 1 The racetrack-shaped double-pancake coil shown in FIG. Figure 3 and Figure 4 As shown, it includes a pay-off mechanism 3, a fixed spindle box 4 and a winding die 5. The winding die 5 is installed on the fixed spindle box 4. The fixed spindle box 4 drives the winding die 5 to rotate. The pay-off mechanism 3 is wound with a positive cake coil winding segment. The pay-off direction of the pay-off mechanism 3 corresponds to the position of the winding die 5, and the winding of the positive cake 1a is performed.

[0072] It also includes a movable spindle box 6 and a pre-winding disk 7. The movable spindle box 6 drives the pre-winding disk 7 to rotate in the same direction relative to the winding mold 5. The pre-winding disk 7 is wound with an inverted coil winding segment to perform the winding of the inverted coil 1b.

[0073] like Figure 3 As shown, the fixed spindle box 4 and the movable spindle box 6 are both installed on a machine base. The fixed spindle box 4 is fixed to the machine base, and a guide track is laid on the machine base. The movable spindle box 6 approaches or moves away from the fixed spindle box 4 along the guide track. Before winding the double-cake coil, the movable spindle box 6 approaches the fixed spindle box 4 until the coils of the positive-cake coil winding segment and the negative-cake coil winding segment are parallel and close to each other; after the winding of the double-cake coil is completed, the movable spindle box 6 is moved away, and the double-cake coil is taken out from the winding mold 5.

[0074] During winding, the unwinding direction of the unwinding mechanism 3 is parallel to and close to the unwinding direction of the pre-winding disk 7; taking the boundary between the positive coil winding segment and the negative coil winding segment as the starting point, after the negative coil winding segment is bent to one side of the positive coil winding segment, the positive coil winding segment and the negative coil winding segment are arranged side by side and close to each other on the winding mold 5.

[0075] The rotation direction of the pre-winding disk 7 is the same as that of the winding mold 5, and the rotation speed of the pre-winding disk 7 is twice the rotation speed of the winding mold 5, so that the rotation speed of the pre-winding disk 7 first offsets the rotation speed of the winding mold 5, and the excess winding speed is used for winding the reverse cake 1b.

[0076] When winding, the raw materials of the conductor all come from the winding drum of the unwinding mechanism 3. Before winding, a section of the conductor is first pulled out and wound on the pre-winding drum 7, i.e., the reverse pancake coil winding section. The length of the reverse pancake coil winding section is at least the length of the conductor of an reverse pancake 1b coil. To save costs, the length of the reverse pancake coil winding section is equal to the length of the conductor of an reverse pancake 1b coil. Preferably, the length of the reverse pancake coil winding section is equal to the length of the conductor of an reverse pancake 1b coil plus the length of the fixed section, wherein the fixed section is used to fix the coil on the pre-winding drum. Since the positive pancake coil winding section comes directly from the winding drum, it can be greater than or equal to the length of the conductor of a positive pancake 1a coil.

[0077] The movable spindle box 6 includes a driving device 1 and a turntable 61 . The driving device 1 drives the turntable 61 to rotate, and the pre-winding disk 7 is fixed to the turntable 61 .

[0078] The fixed spindle box 4 includes a driving device 4 and a turntable 2 41. The driving device 4 drives the turntable 2 41 to rotate, and the winding mold 5 is fixed to the turntable 2 41. The turntable 2 uses a circular drag chain to route the wire. When winding, the turntable 2 rotates 90 degrees in the same direction and speed as the winding mold and then stops rotating.

[0079] The winding die 5 is installed at the center of the second turntable 41. The second turntable 41, the first turntable 61, the winding die 5, and the pre-winding disk 7 are on the same rotating axis. The pre-winding disk 7 is installed at the position of the first turntable 61 near the outer edge of the first turntable 61. The second turntable 41 and the first turntable 61 have the same direction of rotation, and the rotation speed of the first turntable 61 is twice that of the second turntable 41. Figure 4 and Figure 6 As shown, since the pre-winding disk 7 is installed on the turntable 61 near the outer edge of the turntable 61, a counterweight 62 is also provided on the turntable 61 for balance.

[0080] Through the above settings, the technical solution described in this embodiment, due to the provision of a pre-winding disk 7 and a mobile spindle box 6, the rotation speed of the pre-winding disk 7 driven by the mobile spindle box 6 is twice the rotation speed of the winding die 5 driven by the fixed spindle box 4, and the winding speed of the pre-winding disk 7 is used to offset the rotation speed of the winding die 5, and the other is used to wind the wire on the pre-winding disk 7 on the winding die 5. When winding a double-cake coil, there is no need to stop the machine in the middle to flip the positive cake 1a coil, which improves production efficiency; there is no need to perform flanging operations, use tooling, or cut a complete wire for welding. The double-cake coil wound by the technical solution of this embodiment is a complete coil without welding, and the positive cake coil 1a and the reverse cake coil 1b are wound at one time and at the same time.

[0081] In order to ensure the excellent quality of the wound coil, the following settings are further performed:

[0082] like Figure 4 As shown, the pressure wheel device 8 is fixed on the turntable 2 41 and the turntable 1 61 respectively, and the turntable 2 41 and the turntable 1 61 are collectively referred to as turntables; Figure 7 As shown, the pressure wheel device 8 includes a pressure wheel 81 and a mounting seat. The pressure wheel 81 is installed on the turntable through the mounting seat, and the pressure wheel 81 presses on the wire and rotates; the mounting seat includes a spring 82 and a pressure wheel connecting structure, and the pressure wheel 81 is fixed to the pressure wheel connecting structure.

[0083] The mounting base also includes a guide rail 83, a slide 84, a drive device 3 and a proximity switch 85. One end of the spring 82 is fixed to the slide 84, and the other end is connected to the pressure wheel connecting structure, and the pressure wheel connecting structure is fixed with the pressure wheel 81; Figure 7 As shown, two springs 82 are installed on the slide 84; when the pressure wheel 81 rises and falls, the spring 82 is compressed and reset accordingly. The guide rail 83 is installed on the turntable, and the slide 84 is located on the guide rail 83; the drive device 3 drives the slide 84 to move up and down along the guide rail 83; after the spring 82 is compressed, the sensor receives a signal, and the drive device 3 drives the slide 84 to move up and down until the compression amount of the spring 82 reaches the set value, and the signal of the proximity switch 85 disappears.

[0084] A fixed block 86 is also provided on the turntable at one end where the spring 82 is connected to the pressure wheel connecting structure. An inner hole is opened in the fixed block 86. The pressure wheel connecting structure includes a guide rod 87. The guide rod 87 passes through the inner hole of the fixed block 86 and is connected to the end of the spring 82. When the spring 82 is compressed and reset, the guide rod 87 moves up and down along the inner hole of the fixed block 86.

[0085] The third driving device is a motor 88 and a screw nut pair. The motor 88 drives the screw 89 to rotate. The slide 84 is fixed to the screw nut. The screw 89 drives the slide 84 to move up and down along a straight line. Figure 7 As shown, two guide rails 83 are installed on the turntable, and the screw rod 89 is installed between the two guide rails 83.

[0086] like Figure 1 As shown, the shape of the double pancake coil described in this embodiment is a racetrack shape, and the winding part of the winding die 5 is correspondingly a racetrack shape. The racetrack-shaped winding die 5 is different from the cylindrical shape. When the winding die 5 rotates, the pressure wheel 81 fluctuates greatly. In this case, the pressure of the pressure wheel 81 on the wire changes greatly; Figure 7 As shown, a proximity switch 85 is installed between the two springs 82. After the spring 82 is compressed, the proximity switch 85 receives a signal, and the motor 88 drives the screw rod 89 to drive the slide seat 84 to move up and down until the signal of the proximity switch 85 disappears. The proximity switch 85 will disappear until the compression amount of the spring 82 reaches the set value.

[0087] like Figure 8 As shown, a push plate mechanism 10 is also fixed on the turntable 41, and the push plate mechanism 10 includes a push plate 101 and a drive device 5 102. The drive device 5 102 drives the push plate 101 to move to contact the wire and apply pressure to the wire; the drive device 5 102 pushes the push plate 101 to move closer to or away from the coil; the pressure wheel connection structure also includes a connecting seat 90 and a drive device 6 91; the drive device 6 91 is fixed to the turntable, and the output end of the drive device 6 91 is perpendicular to the turntable, and the output end of the drive device 6 91 is connected to the pressure wheel 81, driving the pressure wheel 81 to extend from the turntable and reset.

[0088] like Figure 3 As shown, the pressure wheel is located directly above, and the position of the push plate and the pressure wheel differs by 90 degrees. The driving device 5 102 drives the push plate 101 to move back and forth to ensure that the pressure of the push plate 101 on the wire is constant. When the pressure wheel 81 encounters the push plate 101, the driving device 6 91 drives the pressure wheel 81 to retract and reset. After the pressure wheel 81 passes the push plate 101, the driving device 6 91 drives the pressure wheel 81 to extend to continue to apply pressure to the wire.

[0089] The pressure wheel connection structure also includes a guide rod 92, such as Figure 7As shown, it includes two guide rods 92, which are respectively located on both sides of the output end of the driving device 6 91. The guide rods 92 pass through the connecting seat 90 and are fixed to the pressing wheel 81 to guide the extension and reset of the pressing wheel 81.

[0090] Driving device five 102 and driving device six 91 are cylinders.

[0091] The driving device 5 102 is fixed to the turntable 2 41 through a bracket, and guide plates 103 are fixed on both sides of the push plate 101 to guide the movement of the push plate 101.

[0092] like Fig. 9 As shown, guide plates 103 are fixed on both sides of the push plate 101 to guide the movement of the push plate 101. The push plate 101 includes a push plate 1 101a and a push plate 2 101b arranged in parallel. L-shaped guide rails 104 are respectively provided on the guide plates 103 on both sides; one end of the L-shaped guide rail 104 is perpendicular to the coil, called a vertical guide rail; the other end is in an inclined state, called an inclined guide rail, and the inclined guide rail is inclined toward the direction of the turntable 2 41. A guide bar 105 is fixed on the push plate 2 101b, and the length of the guide bar 105 is less than or equal to the width of the push plate 2 101b. A guide groove 106 is fixed on the push plate 1 101a.

[0093] The driving device 5 102 pushes the push plate 1 101a to move along the inclined guide rail, and the push plate 2 101b gradually extends from the guide plate 103 along the inclined guide rail. After entering the vertical guide rail, the push plate 101a and the push plate 2 101b move relative to each other, that is, the guide bar 105 of the push plate 101a moves along the guide groove 106, and the push plate 2 101b further extends from the guide plate 103 to apply pressure to the double pancake coil; the width of the push plate 2 101b extending is greater than or equal to the width of the double pancake coil. The driving device 5 102 shrinks, and the push plate 2 101b moves away from the double pancake coil along the L-shaped guide rail 104, so that the push plate 2 101b shrinks into the guide plate 103.

[0094] like Figure 5 As shown, the pay-off mechanism 3 is also provided with a wire wheel 31, and the positive pancake coil winding segment passes through the wire wheel 31, and the wire wheel 31 guides the positive pancake coil winding segment.

[0095] The winding device of the continuous pancake coil provided in this embodiment is provided with a mobile spindle box 6 on the basis of the existing double pancake coil winding machine. More cleverly, a pre-winding disk 7 is provided on the turntable 61 of the mobile spindle box 6, and the direction of the pre-winding disk 7 is the same as that of the winding die 5. The winding die 5 is equivalent to the earth, which rotates on its own, and the pre-winding disk 7 is equivalent to the moon, which rotates around the winding die 5. In order to wind the positive pancake 1a and the reverse pancake 1b at the same time, if the pre-winding disk 7 wants to wind the wire on the winding die 5, first the speed of the pre-winding disk 7 must be greater than the speed of the winding die 5, and the speed of the pre-winding disk 7 is first offset by the speed of the winding die 5, and the excess speed is used to wind the wire on the winding die 5. This embodiment is used to wind the runway type double pancake coil, the speed of the pre-winding disk 7 is twice the speed of the winding die 5, and the relative speed between the pre-winding disk 7 and the winding die 5 is also the speed of the winding die 5, so that the positive pancake 1a and the reverse pancake 1b are wound at the same time.

[0096] When in use, a section of wire is pulled out from the winding reel of the wire release mechanism, and the wire is wound on the pre-winding reel, so that the length of the wire wound on the pre-winding reel is equal to the length of the wire of a reverse coil. Before winding, move the mobile spindle box so that the mobile spindle box is close to the fixed spindle box; take the boundary between the positive coil winding segment and the reverse coil winding segment as the starting point, bend the reverse coil winding segment to the side of the positive coil winding segment, and the pressure wheels on the turntable 1 and the turntable 2 are located directly above the winding die and at the tangent point where the wire enters the winding die. Start the fixed spindle box and the mobile spindle box, and the winding die, turntable 1, and turntable 2 rotate in the same direction at the same time, wherein the rotation speed of turntable 1 is twice the rotation speed of the winding die, and turntable 2 stops rotating after rotating 90 degrees with the winding die. The pressure wheel on turntable 1 always rotates with turntable 1, and the pressure wheel and pressure plate on turntable 2 only rotate 90 degrees with turntable 2. In the subsequent winding process, the winding die rotates 90 degrees and stops, and the pressure plate extends to press the coil to make the coil intact. The pressure wheel on turntable 2 does not interfere with the pressure plate. The pressure wheel on turntable 1 rotates with turntable 1, the winding die pauses, and the pressure plate presses the coil. After the pressure plate is pressed, it is immediately retracted. During the rotation of turntable 1, the pressure wheel and the pressure plate will not interfere with each other. Finally, the winding of the positive and negative coils is completed at the same time.

[0097] The technical solution of this embodiment, on the other hand, can be based on actual needs, turntable one and turntable two can rotate forward and reverse, and two positive pancake coils can be wound at the same time, two negative pancake coils can be wound at the same time, or one positive pancake coil and one negative pancake coil can be wound at the same time.

[0098] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the scope of the present invention.

Claims

1. A continuous pancake coil winding device, comprising a pay-off mechanism, a fixed spindle box and a winding die, wherein the winding die is mounted on the fixed spindle box, and the fixed spindle box drives the winding die to rotate to wind the wire on the pay-off mechanism onto the winding die; characterized in that: It also includes a movable spindle box and a pre-winding disk, the movable spindle box drives the pre-winding disk to rotate around the winding die; the winding die is located between the fixed spindle box and the movable spindle box, the pay-off mechanism is wound with a positive coil winding segment, and the pre-winding disk is wound with a negative coil winding segment; the winding die and the pre-winding disk rotate coaxially and in the same direction, and the pre-winding disk rotates faster than the winding die, so that the positive coil winding segment is wound on the winding die at a speed A, and the negative coil winding segment is wound on the winding die in the opposite direction at a speed greater than A.

2. The continuous pancake coil winding device according to claim 1, characterized in that: The mobile spindle box comprises a driving device 1 and a turntable 1. The driving device 1 drives the turntable 1 to rotate. The rotation axis of the turntable 1 coincides with that of the winding die. The pre-winding disk is installed at a position of the turntable 1 close to the outer edge of the turntable 1.

3. The continuous pancake coil winding device according to claim 2, characterized in that: The rotation speed of turntable 1 is twice that of the winding die.

4. The continuous pancake coil winding device according to claim 2, characterized in that: The fixed spindle box includes a turntable 2 and a driving device 2, and the turntable 2 is coaxial with the winding die; the driving device 2 drives the winding die to rotate; the turntable 1 and the turntable 2 are respectively fixed with a pressure wheel device, and the turntable 1 and the turntable 2 are collectively referred to as turntables; the pressure wheel device includes a pressure wheel and a mounting seat, and the pressure wheel is mounted on the turntable through the mounting seat, and the pressure wheel presses on the wire on the winding die; the mounting seat includes a compression device and a pressure wheel connecting structure, one end of the compression device is fixed to the turntable, and the other end is connected to the pressure wheel connecting structure, and a pressure wheel is fixed on the pressure wheel connecting structure; when the pressure wheel rises and falls, the compression device is compressed and reset accordingly.

5. The continuous pancake coil winding device according to claim 4, characterized in that: The mounting seat also includes a guide rail, a slide, a drive device and a sensor. The compression device is fixed to the turntable through the guide rail and the slide. The guide rail is installed on the turntable, and the slide is located on the guide rail. The drive device drives the slide to move up and down along the guide rail. After the compression device is compressed, the sensor receives a signal, and the drive device drives the slide to move up and down until the compression amount of the compression device reaches the set value, and the signal of the sensor disappears.

6. The continuous pancake coil winding device according to claim 5, characterized in that: The third driving device is a motor and a screw-nut pair. The motor drives the screw to rotate, the slide is fixed to the nut, and the screw drives the slide to move up and down along a straight line.

7. The continuous pancake coil winding device according to claim 4, characterized in that: The fixed spindle box also includes a driving device four, which drives the turntable two to rotate. The turntable two is also fixed with a push plate and a driving device five. The driving device five drives the push plate to move to contact the wire and apply pressure to the wire; the driving device five pushes the push plate to move closer to or away from the coil.

8. The insulation tape wrapping device for narrow span motor coils according to claim 7, characterized in that: Guide plates are also fixed on both sides of the push plate. The guide plates are vertically installed on turntable two. The guide plates serve as moving guides for the push plate. The push plate includes push plate one and push plate two arranged in parallel. L-shaped guide rails are respectively provided on the guide plates on both sides. The push plate approaches or moves away from the double-pancake coil along the L-shaped guide rails; push plate one is connected to the output end of the driving device five, and push plate two is movably connected to push plate one in a direction perpendicular to turntable two. One end of the L-shaped guide rail is perpendicular to the coil, which is called a vertical guide rail; the other end is in an inclined state, which is called an inclined guide rail, and the inclined guide rail is inclined toward the direction of turntable two.

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