A new manufacturing method for one-piece molded inductor with high reliability

Abstract

The invention discloses a novel manufacturing method of an integrated inductor with high reliability, comprising: pressing alloy metal particles into a rectangular parallelepiped magnetic core, then cutting the rectangular parallelepiped magnetic core into wire slot holes by a cutting mechanism and baking the core; then silver-dipping and baking the wire slot holes of the baked rectangular parallelepiped magnetic core to form a metal electrode bottom layer, winding enameled wire on the rectangular parallelepiped magnetic core forming the metal electrode bottom layer as required, placing the wound magnetic core into a mold, then encapsulating alloy powder magnetic glue into the mold, then baking and fixing the mold to obtain a molded product, and finally electroplating copper, electroplating nickel and electroplating tin on the molded product, then inspecting and selecting the appearance for packaging and storage. The yield rate of the integrated inductor produced by the method is greatly improved, and the overall cost is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of inductor manufacturing, and more specifically, to a novel manufacturing method of an integrally formed inductor with high reliability. Background Art

[0002] At present, there are two methods for manufacturing one-piece molded inductors: 1. Wrap the hollow coil and place it in the die cavity of the press, add alloy particles, press and form, apply insulating paint, laser peel (or polish and peel), electroplate copper, nickel, tin, test characteristics, select appearance, package and store; 2. Use alloy particles to press T-shaped magnetic cores, wind flat enameled wires on the T-shaped magnetic cores, put the wound magnetic cores into the die cavity of the press, add alloy particles, hot press and form, bake, apply insulating paint, laser peel (or polish and peel), electroplate copper, nickel, tin, test characteristics, select appearance, package and store; the above two existing production methods are suitable for producing large-sized one-piece molded inductors. When producing smaller-sized one-piece molded inductors, the yield rate is very low, and the product reliability is also poor, which limits its use, and the comprehensive cost of the product is high and the selling price is high. Therefore, it is necessary to propose a new manufacturing method of one-piece molded inductors with high reliability to at least partially solve the problems existing in the prior art. Summary of the invention

[0003] A series of simplified concepts are introduced in the Summary of the Invention, which will be further described in detail in the Detailed Description of the Invention. The Summary of the Invention does not mean to attempt to define the key features and essential technical features of the claimed technical solution, nor does it mean to attempt to determine the scope of protection of the claimed technical solution.

[0004] In order to at least partially solve the above problems, the present invention provides a novel manufacturing method of an integrated inductor with high reliability, comprising:

[0005] Step 1: Pressing alloy metal particles into a rectangular magnetic core;

[0006] Step 2: Cut the rectangular magnetic core into wire slots through a cutting mechanism and then bake it;

[0007] Step 3: Silver-coat and bake both sides of the wire slot holes of the baked rectangular magnetic core to form a metal electrode bottom layer;

[0008] Step 4: Wind the enameled wire on the rectangular magnetic core forming the bottom layer of the metal electrode as required;

[0009] Step 5: Place the wound magnetic core into a mold, fill the alloy powder magnetic glue into the mold, and then bake and fix it to obtain a molded product;

[0010] Step 6: The molded products are electroplated with copper, nickel and tin, and then inspected and sorted for appearance before packaging and storage.

[0011] Preferably, in step 5, the bottom layer of the metal electrode needs to be exposed when the alloy powder magnetic glue is poured.

[0012] Preferably, the cutting mechanism comprises:

[0013] The frame body has a grinding disc device at the top of the inner wall of the frame body and a sliding device at the bottom of the inner wall of the frame body.

[0014] Preferably, the grinding disc device comprises:

[0015] A first electric telescopic rod, wherein the top end of the first electric telescopic rod is arranged at the top end of the inner wall of the frame, the bottom end of the first electric telescopic rod is provided with a motor block, the motor block is provided with a cutting motor, and the first electric telescopic rod and the cutting motor are both electrically connected to a controller;

[0016] A first rotating rod, one end of which is connected to the motor block, and the other end of which is connected to the grinding disc.

[0017] Preferably, the sliding device comprises:

[0018] Electric slides, two of which are arranged at the bottom of the inner wall of the frame, an electric slider is slidably connected in the electric slides, a fixing block is fixed on the top of the electric slider, and the electric slider is electrically connected to the controller;

[0019] A fixing groove, the fixing groove is arranged at the top of the fixing block, a limit block is arranged at the bottom end of the inner wall of the fixing groove, and a clamping device is symmetrically arranged on the inner wall of the fixing groove, and the clamping device includes:

[0020] A fixing plate is slidably connected in the fixing groove, a second electric telescopic rod is provided between the fixing plate and the inner wall of the fixing groove, and the second electric telescopic rod is electrically connected to the controller.

[0021] Preferably, a silicone pad is provided on a side of the fixing plate away from the second electric telescopic rod.

[0022] Preferably, a discharge device is provided at the bottom end of the inner wall of the frame, and the discharge device comprises:

[0023] A cross bar, both ends of which are connected to the top of the inner wall of the frame through a fixing rod, and a plurality of detectors are evenly arranged at the bottom end of the cross bar;

[0024] A discharge hole is arranged at the bottom end of the inner wall of the frame, and a switching device is arranged in the discharge hole.

[0025] Preferably, the detector comprises: a mounting plate, the mounting plate is arranged at the bottom end of the cross bar, a second rotating rod is rotatably arranged on the mounting plate, swing rods are fixedly arranged at both ends of the second rotating rod, a third rotating rod is arranged between two adjacent swing rods, a detection wheel is sleeved on the third rotating rod, a pressure sensor is arranged on the detection wheel, and the pressure sensor is electrically connected to the controller;

[0026] A torsion spring, wherein the torsion spring is sleeved on the second rotating rod and is located between the mounting plate and the swing rod;

[0027] A limit rod, wherein the limit rod is arranged on the mounting plate, and the limit rod is located on one side of the swing rod.

[0028] Preferably, the switching device comprises:

[0029] A plate trough, the plate trough being arranged on the inner wall of the discharge hole, a rotating motor being arranged on the inner wall of the plate trough, and the rotating motor being electrically connected to a controller;

[0030] a fourth rotating rod, one end of which is connected to the rotating motor, and the other end of which extends into the plate slot and is connected to the baffle;

[0031] The collecting chamber is arranged on the inner wall of the frame and is communicated with the plate groove.

[0032] Preferably, the grinding disc is made of chrome steel alloy.

[0033] Compared with the prior art, the present invention has at least the following beneficial effects:

[0034] The novel manufacturing method of an integrated inductor with high reliability described in the present invention comprises the following steps: pressing alloy metal particles into a rectangular magnetic core, cutting the rectangular magnetic core into wire slots by a cutting mechanism and baking the core; then silver-dipping and baking the wire slots on both sides of the baked rectangular magnetic core to form a metal electrode bottom layer, winding the enameled wire on the rectangular magnetic core forming the metal electrode bottom layer as required, placing the wound magnetic core into a mold, and then encapsulating the alloy powder magnetic glue into the mold, and then baking and fixing the mold to obtain a molded product; finally, electroplating the molded product with copper, nickel and tin, and then inspecting and selecting the appearance for packaging and storage. The yield rate of the integrated inductor produced by the above method is greatly improved, and the overall cost is reduced.

[0035] The present invention describes a novel method for manufacturing an integrated inductor with high reliability. Other advantages, objectives and features of the present invention will be partially reflected in the following description, and will also be understood by technicians in this field through research and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0037] Figure 1 It is a schematic diagram of a process of a novel manufacturing method of an integrated inductor with high reliability according to the present invention;

[0038] Figure 2 It is a structural schematic diagram of a cutting mechanism of a novel manufacturing method of an integrated molded inductor with high reliability according to the present invention;

[0039] Figure 3 It is a side schematic diagram of a sliding device of a novel manufacturing method of an integrated inductor with high reliability according to the present invention;

[0040] Figure 4 It is a structural schematic diagram of a discharge device of a novel manufacturing method of an integrally formed inductor with high reliability according to the present invention;

[0041] Figure 5 The invention provides a novel manufacturing method of an integrated inductor with high reliability Figure 4 Schematic diagram at A in the middle;

[0042] Figure 6 It is a structural schematic diagram of a switching device of a novel manufacturing method of an integrated molded inductor with high reliability according to the present invention;

[0043] Figure 7 It is a side schematic diagram of a switching device of a novel manufacturing method of an integrated inductor with high reliability according to the present invention;

[0044] Figure 8 It is a top view schematic diagram of an automatic feeding device of a novel manufacturing method of an integrated molded inductor with high reliability according to the present invention;

[0045] Fig. 9 It is a side schematic diagram of an automatic feeding device of a novel manufacturing method of an integrated molded inductor with high reliability according to the present invention;

[0046] Fig.10 It is a cross-sectional schematic diagram of a correction block of a novel manufacturing method of an integrated inductor with high reliability according to the present invention;

[0047] Fig.11 The figure is a top view schematic diagram of a correction block of a novel manufacturing method of an integrated molded inductor with high reliability according to the present invention.

[0048] Description of the accompanying drawings: 1, frame; 2, grinding disc device; 3, sliding device; 4, first electric telescopic rod; 5, motor block; 6, cutting motor; 7, first rotating rod; 8, grinding disc; 9, fixed block; 10, fixed groove; 11, fixed plate; 12, second electric telescopic rod; 13, electric slider; 14, electric slide; 15, limit block; 16, cross bar; 17, fixed rod; 18, discharge hole; 19, mounting plate; 20, swing rod; 21, limit rod; 22, second rotating rod; 23, torsion spring; 24, third rotating rod; 25, detection wheel; 26, pressure sensor; 27, collection chamber; 2 8. Plate slot; 29. ​​Fourth rotating rod; 30. Rotating motor; 31. Feeding block; 32. Discharging barrel; 33. Correction chamber; 34. Conveyor; 35. Correction block; 36. Electromagnet; 37. Feed inlet; 39. First transmission chamber; 40. Double-axis motor; 41. Grinding slot; 42. Second bevel gear; 43. Grinding wheel; 44. Sixth rotating rod; 45. First bevel gear; 46. Third bevel gear; 47. Second transmission chamber; 48. Fourth bevel gear; 49. Fifth bevel gear; 50. Friction slot; 51. Top surface grinding wheel; 52. Eighth rotating rod; 53. Fifth rotating rod; 54. Seventh rotating rod. DETAILED DESCRIPTION

[0049] The present invention is further described in detail below in conjunction with the accompanying drawings and embodiments so that those skilled in the art can implement the invention with reference to the description.

[0050] It should be understood that the terms such as “having”, “including” and “comprising” used herein do not exclude the existence or addition of one or more other elements or combinations thereof.

[0051] like Figure 1-Figure 11 As shown, the present invention provides a novel manufacturing method of an integrated inductor with high reliability, comprising:

[0052] Step 1: Pressing alloy metal particles into a rectangular magnetic core;

[0053] Step 2: Cut the rectangular magnetic core into wire slots through a cutting mechanism and then bake it;

[0054] Step 3: Silver-coat and bake both sides of the wire slot holes of the baked rectangular magnetic core to form a metal electrode bottom layer;

[0055] Step 4: Wind the enameled wire on the rectangular magnetic core forming the bottom layer of the metal electrode as required;

[0056] Step 5: Place the wound magnetic core into a mold, fill the alloy powder magnetic glue into the mold, and then bake and fix it to obtain a molded product;

[0057] Step 6: The molded products are electroplated with copper, nickel and tin, and then inspected and sorted for appearance before packaging and storage.

[0058] The working principle and beneficial effects of the above technical solution are as follows: alloy metal particles are pressed into a rectangular magnetic core, and then the rectangular magnetic core is cut into wire slot holes by a cutting mechanism and baked; then both sides of the wire slot holes of the baked rectangular magnetic core are dipped in silver and baked to form a metal electrode bottom layer, and the enameled wire is wound on the rectangular magnetic core forming the metal electrode bottom layer as required, the wound magnetic core is placed in a mold, and then the alloy powder magnetic glue is poured into the mold, and then baked to fix the mold to obtain a molded product, and finally, the molded product is electroplated with copper, nickel and tin, and then inspected and packaged for storage after appearance selection. The yield rate of the one-piece molded inductor produced by the above method is greatly improved, and the overall cost is reduced.

[0059] In one embodiment, in step 5, the bottom layer of the metal electrode needs to be exposed when the alloy powder magnetic glue is poured.

[0060] The working principle and beneficial effects of the above technical solution: In actual manufacturing, the bottom layer of the metal electrode is exposed so that the finished molded product can be used normally and is convenient for subsequent processing.

[0061] In one embodiment, the cutting mechanism comprises:

[0062] The frame 1 has a grinding disc device 2 at the top of the inner wall of the frame 1 and a sliding device 3 at the bottom of the inner wall of the frame 1.

[0063] The working principle and beneficial effects of the above technical solution: During actual use, the pressed rectangular magnetic core is placed on the processing station of the sliding device 3, and then the grinding disc device 2 is started to move downward, and then the sliding device 3 is started to move, so as to cut winding grooves on the rectangular magnetic core, thereby facilitating subsequent processing.

[0064] In one embodiment, the grinding disc device 2 comprises:

[0065] A first electric telescopic rod 4, wherein the top of the first electric telescopic rod 4 is arranged at the top of the inner wall of the frame 1, a motor block 5 is arranged at the bottom of the first electric telescopic rod 4, a cutting motor 6 is arranged on the motor block 5, and the first electric telescopic rod 4 and the cutting motor 6 are both electrically connected to a controller;

[0066] A first rotating rod 7 , one end of which is connected to the motor block 5 , and the other end of which is connected to the grinding disc 8 .

[0067] The working principle and beneficial effects of the above technical solution: in actual use, the first electric telescopic rod 4 is started, the first electric telescopic rod 4 is extended, thereby driving the motor block 5 to move downward, the motor block 5 drives the cutting motor 6 to move downward, and then the cutting motor 6 is started, and the cutting motor 6 drives the grinding disc 8 to rotate through the first rotating rod 7, and the grinding disc 8 cuts the passing rectangular magnetic core, thereby cutting out the winding slot, which is convenient for subsequent winding processing.

[0068] In one embodiment, the sliding device 3 comprises:

[0069] Electric slides 14, two of the electric slides 14 are arranged at the bottom end of the inner wall of the frame 1, an electric slider 13 is slidably connected in the electric slides 14, a fixing block 9 is fixed at the top of the electric slider 13, and the electric slider 13 is electrically connected to the controller;

[0070] A fixing groove 10 is provided at the top of the fixing block 9, a limit block 15 is provided at the bottom of the inner wall of the fixing groove 10, and a clamping device is symmetrically provided on the inner wall of the fixing groove 10, and the clamping device includes:

[0071] A fixing plate 11 is slidably connected in the fixing groove 10 , and a second electric telescopic rod 12 is provided between the fixing plate 11 and the inner wall of the fixing groove 10 , and the second electric telescopic rod 12 is electrically connected to a controller.

[0072] The working principle and beneficial effects of the above technical solution are as follows: in actual use, the rectangular magnetic core is placed in the fixed groove 10, and then the second electric telescopic rod 12 is started. The second electric telescopic rod 12 drives the two fixed plates 11 to move toward each other, thereby clamping and fixing the rectangular magnetic core. Then the electric slider 13 is started. The electric slider 13 slides in the electric slide groove 14. The electric slide drives the rectangular magnetic core to move through the fixed block 9, so that the rectangular magnetic core passes through the grinding disc 8, cuts out the winding groove, and then removes the rectangular magnetic core. The electric slider 13 drives the fixed block 9 back to its original position.

[0073] In one embodiment, a silicone pad is provided on a side of the fixing plate 11 away from the second electric telescopic rod 12 .

[0074] The working principle and beneficial effects of the above technical solution: In actual use, the provided silicone pad plays a buffering role in the process of fixing the rectangular magnetic core to prevent the rectangular magnetic core from deforming. At the same time, the silicone can effectively transfer the heat generated during cutting.

[0075] In one embodiment, a discharge device is provided at the bottom end of the inner wall of the frame 1, and the discharge device comprises:

[0076] A cross bar 16, both ends of which are connected to the top of the inner wall of the frame 1 through a fixing rod 17, and a plurality of detectors are evenly arranged at the bottom end of the cross bar 16;

[0077] A discharge hole 18, the discharge hole 18 is arranged at the bottom end of the inner wall of the frame 1, and a switching device is arranged in the discharge hole 18;

[0078] The detector comprises: a mounting plate 19, the mounting plate 19 is arranged at the bottom end of the cross bar 16, a second rotating rod 22 is rotatably provided on the mounting plate 19, swing rods 20 are fixedly provided at both ends of the second rotating rod 22, a third rotating rod 24 is provided between two adjacent swing rods 20, a detection wheel 25 is sleeved on the third rotating rod 24, a pressure sensor 26 is provided on the detection wheel 25, and the pressure sensor 26 is electrically connected to the controller;

[0079] a torsion spring 23, wherein the torsion spring 23 is sleeved on the second rotating rod 22, and the torsion spring 23 is located between the mounting plate 19 and the swing rod 20;

[0080] A limiting rod 21, wherein the limiting rod 21 is disposed on the mounting plate 19, and the limiting rod 21 is located at one side of the swing rod 20;

[0081] The switching device comprises:

[0082] A plate groove 28, wherein the plate groove 28 is disposed on the inner wall of the discharge hole 13, and a rotating motor 30 is disposed on the inner wall of the plate groove 28, and the rotating motor 30 is electrically connected to a controller;

[0083] A fourth rotating rod 29, one end of which is connected to the rotating motor 30, and the other end of which extends into the plate slot 28 and is connected to the baffle 38;

[0084] The collecting chamber 27 is disposed on the inner wall of the frame 1 , and the collecting chamber 27 is communicated with the plate groove 28 .

[0085] The working principle and beneficial effects of the above technical solution are as follows: in actual use, after the grinding disc 8 has cut the rectangular magnetic core, the fixed block 9 continues to drive the rectangular magnetic core to move above the electric slide 14. At this time, the moving front side of the rectangular magnetic core will contact the detection wheel 25. During the continued movement of the rectangular magnetic core, the rectangular magnetic core drives the swing rod 20 to rotate in the direction of movement of the rectangular magnetic core through the detection wheel 25 and the third rotating rod 24, so that the detection wheel 25 slides on the top of the rectangular magnetic core. Under the action of the torsion spring 23, the pressure sensor 26 detects a pressure value; at this time, the detection wheel 25 located in the middle slides through the middle winding slot, and the detection wheel 25 The detected pressure value is recorded as the first pressure value, and the detection wheels 25 located on both sides slide over the tops of both sides of the winding slot. The pressure value detected by the detection wheel 25 is recorded as the second pressure value. After the rectangular magnetic core slides over, the torsion spring 23 drives the swing rod 20 back to its original position, and at the same time, it is determined whether the difference between the first pressure value and the second pressure value is within a preset range. If it is within the preset range, it means that the cutting effect of the winding slot meets the requirements, and the electric slider 13 drives the fixed block 9 back to its original position. In this process, the rectangular magnetic core is pushed out of the fixed slot 10 by the detection wheel 25 under the action of the detection wheel 25, and then falls into the discharge hole 18 and is stacked in the discharge hole 18.

[0086] When the difference is not within the preset range, it means that the depth of the winding slot is too large or too shallow. At this time, the rotating motor 30 is started, and the rotating motor 30 drives the baffle 38 to rotate through the fourth rotating rod 29, so that the baffle 38 leaves the plate slot 28 and extends into the discharge hole 18, so that the discharge hole 18 is connected with the collection chamber 27, so that the defective products entering the discharge hole 18 will enter the collection chamber 27;

[0087] The unloading device provided reduces manual intervention and improves processing efficiency after the cutting of the rectangular magnetic core is completed; and in the unloading process, the unloading device will detect the cut rectangular magnetic core, and the qualified products will fall into the bottom of the unloading hole 18 and be stacked together in sequence to facilitate subsequent transfer processing, while the defective products will be rejected by the unloading device and then collected separately to facilitate subsequent waste treatment, while avoiding the subsequent production of problematic products due to defective products, thereby improving product yield; and the controller will record the number of consecutive defective products. When the number of consecutive defective products exceeds the preset value, the controller will remind the staff to inspect the cutting mechanism.

[0088] In one embodiment, the grinding disc 8 is made of a chrome steel alloy.

[0089] The working principle and beneficial effects of the above technical solution: The grinding disc 8 made of chrome steel alloy can improve the cutting effect and speed of the rectangular parallelepiped magnetic core.

[0090] In one embodiment, an automatic feeding device is further provided at the bottom end of the inner wall of the frame 1, and the automatic feeding device comprises:

[0091] A feeding block 31, the feeding block 31 is arranged at the bottom end of the inner wall of the frame, a correction cavity 33 is arranged in the feeding block 31, a conveyor 34 is arranged at the bottom end of the inner wall of the correction cavity 33, and a plurality of electromagnets 36 are arranged on the conveyor 34, and the conveyor 34 and the electromagnets 36 are electrically connected to the controller;

[0092] Correction blocks 35, a plurality of the correction blocks 35 are arranged on the inner wall of the correction chamber 33, and the correction blocks 35 are provided with inclined surfaces and horizontal surfaces in sequence along the conveying direction of the conveyor 34;

[0093] A discharge cylinder 32, the discharge cylinder 32 is arranged on the inner wall of the correction chamber 33, and the discharge cylinder 32 is located on one side of the conveyor 34;

[0094] A feed inlet 37, the feed inlet 37 is provided at the top of the inner wall of the correction cavity 33;

[0095] A double-axis motor 40, the double-axis motor 40 is arranged on the correction block 35, the double-axis motor 40 is electrically connected to the controller, the double-axis motor 40 is located in the horizontal plane, the two sides of the double-axis motor 40 are symmetrically provided with side grinding devices, and the side of the double-axis motor 40 away from the feed port 37 is provided with a top surface grinding device;

[0096] The side grinding device comprises:

[0097] A first transmission chamber 39, wherein the first transmission chamber 39 is disposed in the correction block 35;

[0098] A grinding groove 41, wherein the grinding groove 41 is disposed on the correction block 35, and the first transmission cavity 39 is located above the grinding groove 41;

[0099] a fifth rotating rod 53, one end of which is connected to the dual-axis motor 40, and the other end of which extends into the first transmission cavity 39 and is connected to the first bevel gear 45;

[0100] A sixth rotating rod 44, one end of which extends into the first transmission cavity 39 and is connected to the second bevel gear 42, the other end of which extends into the grinding groove 41 and is connected to the side grinding wheel 43, and the first bevel gear 45 is meshed with the second bevel gear 42;

[0101] The top surface grinding device comprises:

[0102] A second transmission cavity 47, wherein the second transmission cavity 47 is disposed in the correction block 35, and the second transmission cavity 47 is located at a side of the first transmission cavity 39 away from the feed port 37;

[0103] A seventh rotating rod 54, one end of the seventh rotating rod 54 extends into the first transmission cavity 39 to be connected to the third bevel gear 46, the third bevel gear 46 is meshed with the second bevel gear 42, and the other end of the seventh rotating rod 54 extends into the second transmission cavity 47 to be connected to the fourth bevel gear 48;

[0104] A friction groove 50, wherein the friction groove 50 is provided on the correction block 35, and the friction groove 50 is located at one side of the second transmission cavity 47;

[0105] An eighth rotating rod 52 , one end of which is connected to the fifth bevel gear 49 , which is meshed with the fourth bevel gear 48 , and the other end of which extends into the friction groove 50 and is connected to the top surface grinding wheel 51 .

[0106] The working principle and beneficial effects of the above technical solution are as follows: in actual use, the pressed rectangular magnetic core is fed into the correction chamber 33 through the feed port 37, and the rectangular magnetic core falls onto the conveyor 34. Driven by the conveyor 34, the rectangular magnetic core moves with the conveyor 34. At this time, the rectangular magnetic cores in different directions will contact the inclined surface of the correction block 35, and will be offset under the action of the inclined surface, thereby completing the posture correction; the rectangular magnetic core that has completed the posture correction will enter the horizontal surface of the correction block 35, and the electromagnet 36 on the conveyor located at the horizontal surface position is started, thereby adsorbing and fixing the rectangular magnetic core located at the position of the correction block 35, and at the same time the dual-axis motor 40 is started, and the dual-axis motor 40 is driven by the fifth rotation. The movable rod 53 drives the first bevel gear 45 to rotate, the first bevel gear 45 drives the sixth rotating rod 44 to rotate through the second bevel gear 42, the sixth rotating rod 44 drives the side grinding wheel 43 to rotate, so that the side grinding wheel 43 grinds and trims the two side surfaces of the passing rectangular magnetic core, and the second bevel gear 42 drives the seventh rotating rod 54 to rotate through the third bevel gear 46, the seventh rotating rod 54 drives the fifth bevel gear 49 to rotate through the fourth bevel gear 48, and the fifth bevel gear 49 drives the top surface grinding wheel 51 through the eighth rotating rod 52 to grind the top surface of the passing rectangular magnetic core; after grinding, the rectangular magnetic core will leave the conveyor 34 and then fall from the discharge barrel 32 into the fixed groove 10, completing automatic loading;

[0107] An automatic feeding device is provided to correct the posture of the inserted rectangular magnetic cores, so that rectangular magnetic cores with different postures can be directly placed through the feed port 37, avoiding the need for manual feeding; at the same time, after the correction is completed, the automatic feeding device can grind the side and top surfaces of the rectangular magnetic cores to avoid irregularities in the pressed rectangular magnetic cores, which may cause damage to the enameled wires during subsequent winding, thereby improving the yield of the molded products.

[0108] In one embodiment, in one embodiment, the top surface grinding wheel 51 is made of sponge.

[0109] The working principle and beneficial effects of the above technical solution are as follows: the top surface grinding wheel 51 made of sponge material can quickly absorb the debris and dust in the fixing groove 10 and the friction groove 50 .

[0110] In the description of the present invention, it is to be understood that the terms “center”, “longitudinal”, “lateral”, “length”, “width”, “thickness”, “up”, “down”, “front”, “back”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inside”, “outside”, “clockwise”, “counterclockwise”, “axial”, “radial”, “circumferential”, etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0111] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral one; it can be a mechanical connection, an electrical connection, or communication with each other; it can be a direct connection, or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0112] Although the embodiments of the present invention have been disclosed as above, they are not limited to the applications listed in the specification and the implementation methods. They can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and the illustrations shown and described herein.

Claims

1. A novel method for manufacturing an integrated inductor with high reliability, characterized in that: include: Step 1: Pressing alloy metal particles into a rectangular magnetic core; Step 2: Cut the rectangular magnetic core into wire slots through a cutting mechanism and then bake it; Step 3: Silver-coat and bake both sides of the wire slot holes of the baked rectangular magnetic core to form a metal electrode bottom layer; Step 4: Wind the enameled wire on the rectangular magnetic core forming the bottom layer of the metal electrode as required; Step 5: Place the wound magnetic core into a mold, fill the alloy powder magnetic glue into the mold, and then bake and fix it to obtain a molded product; Step 6: The molded products are electroplated with copper, nickel and tin, and then inspected and packaged for storage according to appearance; The cutting mechanism comprises: A frame (1), wherein a grinding disc device (2) is provided at the top end of the inner wall of the frame (1), and a sliding device (3) is provided at the bottom end of the inner wall of the frame (1); A discharge device is provided at the bottom end of the inner wall of the frame (1), and the discharge device comprises: A cross bar (16), the two ends of the cross bar (16) being connected to the top of the inner wall of the frame (1) via a fixing rod (17), and a plurality of detectors being evenly arranged at the bottom end of the cross bar (16); A discharge hole (18), the discharge hole (18) being arranged at the bottom end of the inner wall of the frame (1), and a switching device being arranged in the discharge hole (18); The grinding disc device (2) comprises: a first electric telescopic rod (4), the top end of the first electric telescopic rod (4) being arranged at the top end of the inner wall of the frame (1), the bottom end of the first electric telescopic rod (4) being provided with a motor block (5), the motor block (5) being provided with a cutting motor (6), the first electric telescopic rod (4) and the cutting motor (6) being both electrically connected to a controller; a first rotating rod (7), one end of the first rotating rod (7) being connected to the motor block (5), and the other end of the first rotating rod (7) being connected to the grinding disc (8); The detector comprises: a mounting plate (19), the mounting plate (19) being arranged at the bottom end of the cross bar (16), a second rotating rod (22) being rotatably arranged on the mounting plate (19), swing rods (20) being fixedly arranged at both ends of the second rotating rod (22), a third rotating rod (24) being arranged between two adjacent swing rods (20), a detection wheel (25) being sleeved on the third rotating rod (24), a pressure sensor (26) being arranged on the detection wheel (25), and the pressure sensor (26) being electrically connected to the controller; a torsion spring (23), the torsion spring (23) being sleeved on the second rotating rod (22), the torsion spring (23) being located between the mounting plate (19) and the swing rod (20); A limiting rod (21), wherein the limiting rod (21) is arranged on the mounting plate (19), and the limiting rod (21) is located on one side of the swing rod (20).

2. A novel method for manufacturing an integrated inductor with high reliability according to claim 1, characterized in that: In step 5, the bottom layer of the metal electrode needs to be exposed when the alloy powder magnetic glue is poured.

3. The novel manufacturing method of an integrated inductor with high reliability according to claim 1, characterized in that: The sliding device (3) comprises: An electric slide groove (14), wherein two electric slide grooves (14) are arranged at the bottom end of the inner wall of the frame (1), an electric slider (13) is slidably connected in the electric slide groove (14), a fixing block (9) is fixed at the top of the electric slider (13), and the electric slider (13) is electrically connected to a controller; A fixing groove (10), the fixing groove (10) being arranged at the top end of the fixing block (9), a limiting block (15) being arranged at the bottom end of the inner wall of the fixing groove (10), and a clamping device being symmetrically arranged on the inner wall of the fixing groove (10), the clamping device comprising: A fixing plate (11), the fixing plate (11) being slidably connected in the fixing groove (10), a second electric telescopic rod (12) being provided between the fixing plate (11) and the inner wall of the fixing groove (10), the second electric telescopic rod (12) being electrically connected to a controller.

4. The novel manufacturing method of an integrated inductor with high reliability according to claim 3, characterized in that: A silicone pad is provided on a side of the fixing plate (11) away from the second electric telescopic rod (12).

5. The novel manufacturing method of an integrated inductor with high reliability according to claim 1, characterized in that: The switching device comprises: A plate groove (28), the plate groove (28) being arranged on the inner wall of the discharge hole (18), a rotating motor (30) being arranged on the inner wall of the plate groove (28), and the rotating motor (30) being electrically connected to a controller; a fourth rotating rod (29), one end of the fourth rotating rod (29) being connected to the rotating motor (30), and the other end of the fourth rotating rod (29) extending into the plate groove (28) and connected to the baffle plate (38); A collecting chamber (27), wherein the collecting chamber (27) is arranged on the inner wall of the frame body (1), and the collecting chamber (27) is communicated with the plate groove (28).

6. The novel method for manufacturing an integrated inductor with high reliability according to claim 1, characterized in that: The grinding disc (8) is made of a chrome steel alloy.

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