Method for forming a semi-spherical skeleton-free coil

Abstract

The application belongs to the technical field of coil forming, and specifically provides a semi-spherical skeleton-free coil forming method, single-coil winding is realized through a winding device, preforming of single coil is realized through a preforming device, and finally semi-spherical skeleton-free coil forming is realized through assembling in a forming device and high-temperature curing; the problem that semi-spherical skeleton-free coil cannot realize distributed curing forming in the prior art is solved, step-by-step forming of semi-spherical skeleton-free coil is realized, and the size precision and stability of skeleton-free coil are effectively improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of coil forming, and particularly relates to a method for forming a semi-spherical skeleton-free coil. BACKGROUND

[0002] At present, a torque device composed of a coil and a magnet is increasingly mature in the field of ammunition products, and has the characteristics of low cost, simple driving circuit and compact structure. With the development of science and technology, the requirements of ammunition products for electromagnetic torque devices are increasingly improved. In particular, in the precise guidance seeker for providing tracking and positioning for a weapon system, an electromagnetic torque device with a more complex structure and more powerful function is needed. To meet the technical index requirements of a large frame angle range, a large tracking angular velocity and a search angular velocity of a laser guidance seeker, a new type of torque device composed of a semi-spherical skeleton-free coil and a spherical magnet is widely used.

[0003] The coil, as an important component of the torque device, provides an effective precession torque in the internal driving mechanism of the laser guidance seeker, and realizes real-time tracking of the seeker to the target. The forming quality of the coil is crucial to the normal operation of the torque device. The conventional coil is mainly a ring-shaped wire winding, which has a simple structure and a mature forming process. The semi-spherical skeleton-free coil has a semi-spherical shape, and is composed of four groups of independent coils without internal skeleton support. Each group of coils is distributed in 1 / 4 of a spherical surface, and two coils are combined into a pair. The four groups of independent coils are combined into a whole coil. The semi-spherical skeleton-free coil has a complex structure, and there is no mature forming process method.

[0004] A patent document with the publication number CN105529177B and the publication date of November 10, 2017 discloses a mold for winding a stepped skeleton-free coil winding, which comprises a base including a ring-shaped bottom plate and a fixed cylinder, and a mandrel provided in the fixed cylinder; a mold core provided on the outer wall of the fixed cylinder; a coil blocking piece provided on the outer wall of the mandrel, which comprises a ring-shaped baffle and a cylinder concentrically fixed to the top of the ring-shaped baffle, and the inner wall of the ring-shaped baffle and the inner wall of the cylinder are in cooperation with the outer wall of the mandrel; the outer wall of the mandrel is provided with a locking nut in threaded cooperation with the mandrel, and the bottom of the locking nut is in cooperation with the top of the cylinder; a coil limiting cover, which comprises a ring-shaped limiting plate and a cover cylinder concentrically fixed to the bottom of the ring-shaped limiting plate, and the ring-shaped limiting plate is sleeved on the outer wall of the cylinder; during winding, the outer diameter of the coil is limited within the coil limiting cover due to the action of the coil limiting cover, and a stepped skeleton-free coil winding is obtained; the structure is simple, convenient to use, and can quickly wind the coil. However, this document cannot realize the forming of the semi-spherical skeleton-free coil. SUMMARY

[0005] The semi-spherical skeleton-free coil forming method provided by the present application aims to overcome the problem that the semi-spherical skeleton-free coil cannot be formed by distribution curing in the prior art.

[0006] To this end, the application provides a semi-spherical skeleton-free coil forming method, comprising the following steps:

[0007] 1) mounting a winding device on a winding machine, setting winding parameters on the winding machine, and winding the wire into the wire slot of the winding device;

[0008] 2) starting the winding machine, and after the winding machine completes the winding according to the set winding parameters, dismounting the winding device and taking out the wound coil;

[0009] 3) loading the single coil in the wound coil into a preforming device, coating glue on the surface of the loaded coil, pressing the single coil coated with glue through the preforming device, and then airing the coil to shape at room temperature, dismounting the preforming device, and taking out the shaped coil to complete the preforming of the single coil;

[0010] 4) coating lubricating grease on the inner surface of each component in the forming device, loading the four preformed coils into the forming device according to two-by-two, fastening the forming device, and then high-temperature drying, after the drying is completed, airing the forming device at room temperature for a set time, dismounting the forming device, and taking out the coil, which is a semi-spherical skeleton-free coil.

[0011] Preferably, the winding device comprises a winding shaft, a first sleeve, a first stop block, a baffle one, a cylindrical pin, a mandrel, a baffle two, a nut, a second sleeve, and a second stop block, the first sleeve, the first stop block, the baffle one, the mandrel, the baffle two, the second stop block, the second sleeve, and the nut are sequentially sleeved on the outside of the winding shaft from left to right, and the cylindrical pin is sequentially inserted into the baffle one, the mandrel, and the baffle two.

[0012] Preferably, the baffle one and the baffle two are the same shape and are symmetrically distributed around the mandrel, a plurality of wire slots are formed on the baffle one, and the plurality of wire slots are symmetrically distributed along the circumference.

[0013] Preferably, the preforming device comprises a pre-bottom plate, a pre-stop block, a pre-cover plate, a pre-pressing plate, and a pre-side plate; the pre-bottom plate comprises a pre-upper plate and a pre-lower plate, the pre-upper plate is a semi-cylindrical plate, the pre-lower plate is a semi-circular plate, the pre-side plate is a semi-circular arc plate, the radius of the pre-lower plate is greater than the radius of the pre-upper plate, the upper surface of the circular arc of the pre-lower plate is connected to the pre-side plate, the outer side of the diameter of the pre-lower plate is connected to the pre-stop block, the left segment and the right segment of the pre-stop block are each connected to a pre-pressing plate, and the upper surface of the pre-lower plate is connected to the pre-cover plate through the pre-upper plate, and the pre-upper plate is located between the pre-side plate and the pre-stop block.

[0014] Preferably, the pre-cover plate comprises an upper cover plate and a lower cover plate, the upper cover plate is connected to the lower cover plate, the shape of the upper cover plate is a semi-circle, and the shape of the lower cover plate is a semi-circular arc, and the radius of the upper cover plate is greater than the radius of the lower cover plate.

[0015] Preferably, the pre-stop plate comprises a first stop plate, a second stop plate and a third stop plate, the first stop plate, the second stop plate and the third stop plate are vertically arranged and sequentially connected from back to front, the upper middle part of the first stop plate is a first protrusion upward, the first protrusion and the third stop plate are symmetrically arranged front and back with the second stop plate as the center surface, the shapes of the first protrusion, the second stop plate and the third stop plate are all arc-shaped, the lower surface of the second stop plate and the lower surface of the first stop plate are located on the same horizontal plane, and the arc surface of the second stop plate is lower than the arc surface of the third stop plate.

[0016] Preferably, the pre-pressing plate connected to the left segment of the pre-stop plate comprises a pressing upper plate and a pressing lower plate, the lower middle part of the pressing upper plate is connected to the pressing lower plate, and the pressing lower plate is arc-shaped.

[0017] Preferably, the forming device comprises a base, a support seat, a support frame, a positioning frame, a positioning ring and a top cover, which are sequentially connected from bottom to top.

[0018] Preferably, the support frame comprises two support plates, the middle parts of the two support plates are perpendicularly connected to each other, the support plates are arc-shaped, and the linear surfaces of the arc-shaped support plates are connected to the support seat.

[0019] Preferably, the positioning frame comprises a frame bottom and a center body, the frame bottom is circular ring-shaped, the inner circle of the circular ring-shaped frame bottom is tangent to the bottom of the center body, the lower part of the center body is a cylinder, the upper part of the center body is a hemisphere, and a cross-shaped groove is formed in the center axis of the center body upward.

[0020] The beneficial effects of the present application are as follows:

[0021] 1. The hemispherical skeleton-free coil forming method provided by the present application realizes single-group coil winding through the winding device, realizes single-group coil preforming through the preforming device, and finally realizes the forming of the hemispherical skeleton-free coil through assembly and high-temperature curing in the forming device; the step-by-step forming method effectively improves the size precision and stability of the skeleton-free coil, solves the broken wire problem caused by flying wire and springback in the hemispherical coil forming process, and provides a reliable forming method for the hemispherical skeleton-free coil.

[0022] 2. The hemispherical skeleton-free coil forming method provided by the present application, after the pre-base plate, the pre-stop plate, the pre-cover plate, the pre-pressing plate and the pre-side plate are assembled, a single-coil-shaped cavity is formed in the preforming device, and the preforming of the single-group coil is realized.

[0023] 3. The hemispherical skeleton-free coil forming method provided by the present application, the middle parts of the two support plates of the support frame are perpendicularly connected to each other (cross-shaped), and the support plates are arc-shaped, the linear surfaces of the arc-shaped support plates are connected to the support seat, the center "cross" of the support frame is completely attached to the inner circle of the coil, and the stability of the coil size during disassembly is ensured. Attached Figure Description

[0024] The present invention will now be described in further detail with reference to the accompanying drawings.

[0025] Figure 1 A schematic diagram of a hemispherical frameless coil structure;

[0026] Figure 2 This is a front view of the winding device.

[0027] Figure 3 This is a left view of the winding device.

[0028] Figure 4 Here are the structural views of the preforming device;

[0029] Figure 5 This is a structural assembly diagram of the preforming device;

[0030] Figure 6 This is a structural view of the molding device.

[0031] Explanation of reference numerals in the attached drawings: 1. Winding device; 1-1. Wire binding groove; 1-2. Winding shaft; 1-3. First sleeve; 1-4. First stop block; 1-5. Baffle one; 1-6. Cylindrical pin; 1-7. Mandrel; 1-8. Baffle two; 1-9. Nut; 1-10. Second sleeve; 1-11. Second stop block; 2. Pre-forming device; 2-1. Pre-bottom plate; 2-2. Pre-baffle; 2-3. Pre-cover plate; 2-4. Pre-pressing plate; 2-5. Pre-side plate; 2- 11. Pre-upper plate; 2-12. Pre-lower plate; 2-31. Upper cover plate; 2-32. Lower cover plate; 2-21. First stop plate; 2-22. Second stop plate; 2-23. Third stop plate; 2-41. Upper pressure plate; 2-42. Lower pressure plate; 3. Forming device; 4. Base; 5. Support seat; 6. Support frame; 6-1. Support plate; 7. Positioning frame; 7-1. Frame bottom; 7-2. Central body; 8. Positioning ring; 9. Top cover; 9-1. Handrail; 9-2. Carding platform. Detailed Implementation

[0032] Example 1:

[0033] like Figure 1 , Figure 2 -4. Figure 6 As shown, a method for forming a hemispherical frameless coil includes the following steps:

[0034] 1) Install the winding device 1 on the winding machine, set the winding parameters on the winding machine, and tie the wire into the wire tying groove 1-1 of the winding device 1; the winding parameters include the number of winding turns, starting position, tension, rotation speed, wire width and other parameters, which are set according to the specific situation when using it;

[0035] 2) start the winding machine, after the winding machine completes the winding according to the set winding parameters, remove the winding device 1 and take out the wound coil;

[0036] Preferably, after the winding according to the set winding parameters is completed, the wound coil is bundled with cotton thread before being taken out; the coil can be wound with cotton thread and tied with double knots for bundling, preventing the coil from loosening and rebounding; in actual operation, the cotton thread for bundling the coil can be replaced with other types of thread.

[0037] 3) load the single group of wound coils into the preforming device 2, coat the surface of the loaded coils with glue, press the glued single group of coils through the preforming device 2, then air dry at room temperature until the coils are shaped, remove the preforming device 2 and take out the shaped coils, completing the preforming of the single group of coils;

[0038] Preferably, air dry at room temperature for no less than 2 hours; in the shortest time, ensure the shaping effect.

[0039] 4) coat the inner surface of each component in the forming device 3 with lubricating grease, load the four groups of preformed coils into the forming device 3 according to two-by-two pairing, tighten the forming device 3 and perform high-temperature drying, after the drying is completed, air dry the forming device 3 at room temperature for a set time, then remove the forming device 3 and take out the coils, which are the semi-spherical frameless coils.

[0040] Preferably, the high-temperature drying time is 2.5±0.2 hours, and the air drying at room temperature is no less than 3 hours. The forming effect is better.

[0041] The semi-spherical frameless coil forming method provided by the application realizes the winding of a single group of coils through the winding device 1, realizes the preforming of a single group of coils through the preforming device 2, and finally realizes the forming of semi-spherical frameless coils through the assembly and high-temperature curing in the forming device 3; the step-by-step forming method effectively improves the size precision and stability of the frameless coil, solves the problem of broken wires caused by flying wires and rebounding in the forming process of semi-spherical coils, and provides a reliable forming method for semi-spherical frameless coils.

[0042] Example 2:

[0043] On the basis of example 1, a winding device, the winding device 1 comprises a winding shaft 1-2, a first sleeve 1-3, a first stopper 1-4, a baffle 1-5, a cylindrical pin 1-6, a mandrel 1-7, a second baffle 1-8, a nut 1-9, a second sleeve 1-10 and a second stopper 1-11, the first sleeve 1-3, the first stopper 1-4, the baffle 1-5, the mandrel 1-7, the second baffle 1-8, the second stopper 1-11, the second sleeve 1-10 and the nut 1-9 are sequentially sleeved on the outside of the winding shaft 1-2 from left to right, and the cylindrical pin 1-6 is sequentially inserted into the baffle 1-5, the mandrel 1-7 and the second baffle 1-8.

[0044] The first sleeve 1-3, the first block 1-4, the baffle one 1-5, the mandrel 1-7, the baffle two 1-8, the second block 1-11 and the second sleeve 1-10 are sleeved on the outside of the winding shaft 1-2 through the through holes on the respective central axes and are fastened through the nut 1-9, the cylindrical pin 1-6 is installed on the first block 1-4, the mandrel 1-7 and the second block 1-11, and the cylindrical pin 1-6 is installed through the positioning holes on the mandrel 1-7 and the second block 1-11, so that the positions of the first block 1-4, the mandrel 1-7 and the second block 1-11 are fixed.

[0045] In the winding process, the winding machine main shaft (the winding machine is an existing device, and details are not described here) drives the winding device 1 as a whole to rotate through the winding shaft 1-2, the first sleeve 1-3, the first block 1-4, the second block 1-11 and the second sleeve 1-10 are mainly used for adjusting the winding starting position, the first block 1-4 and the second block 1-11 are used to limit the winding width, and the mandrel 1-7 is mainly used to control the diameter of the winding coil.

[0046] Compared with the existing device, the winding device 1 of the present application adds the first sleeve 1-3, the first block 1-4, the second block 1-11 and the second sleeve 1-10, realizes the adjustable winding starting position, and increases the versatility of the winding device; the cylindrical pin 1-6 is designed as the positioning pin of the first block 1-4, the mandrel 1-7 and the second block 1-11, which improves the positioning accuracy of the mandrel 1-7 and avoids the problem that the mandrel 1-7 is out of synchronization with the winding device rotation, causing inaccurate winding turns.

[0047] Preferably, the diameter of the mandrel 1-7 is the same as the minimum inner diameter of a single coil, and the thickness of the mandrel 1-7 determines the width range of the coil winding, which is determined by the size and turns of the coil. Since the size of the mandrel 1-7 determines the single coil forming size and the final resistance value, according to the calculation of the coil shape size, the minimum circumference of a single coil is 284mm, and the corresponding diameter is 90.5mm.

[0048] Preferably, the baffle one 1-5 and the baffle two 1-8 are the same shape and are symmetrically distributed around the mandrel 1-7, a plurality of wire tying grooves 1-1 are formed on the baffle one 1-5 and the plurality of wire tying grooves 1-1 are symmetrically distributed along the circumference.

[0049] The baffle one 1-5 and the baffle two 1-8 have a concentric limiting effect. The setting and distribution of the wire tying grooves 1-1 ensure that the coil is not loose during the disassembly process after winding; the symmetric distribution of the plurality of wire tying grooves 1-1 along the circumference ensures that the distribution position of the bundled cotton thread is reasonable, and the coil is not easy to loosen; preferably, the number of the wire tying grooves 1-1 is 4.

[0050] Preferably, the cord groove 1-1 is opened along the circumferential outside to the center direction. It plays a limiting role for the coil and facilitates the winding of the coil.

[0051] Preferably, the outer diameter of the winding shaft 1-2 outside the left side of the first sleeve 1-3 is greater than the outer diameter of the winding shaft 1-2 outside the right side of the second sleeve 1-10.

[0052] That is, the outer diameter of the left end of the winding shaft 1-2 is greater than the outer diameter of the right end of the winding shaft 1-2. According to the shaft connection requirements of the winding machine spindle, the diameter of the left end of the winding shaft 1-2 is Φ32mm, and the diameter of the right end of the winding shaft 1-2 is Φ16mm.

[0053] Preferably, the outer diameter of the mandrel 1-7 is smaller than the outer diameter of the baffle 1-5; to ensure that the baffle 1-5 and the baffle 2 1-8 have a concentric limiting effect.

[0054] The working principle of the winding device is:

[0055] When winding, the wire is arranged in the cord groove, the winding machine spindle drives the winding device 1 as a whole to rotate for winding, the first sleeve 1-3, the first stop block 1-4, the second stop block 1-11 and the second sleeve 1-10 are used to adjust the starting position of winding, the first stop block 1-4 and the second stop block 1-11 are used to limit the winding width, and the mandrel 1-7 is used to control the diameter of the winding coil.

[0056] Example 3:

[0057] As shown in Figure 5 On the basis of example 2, a preforming device, the preforming device 2 includes a pre-bottom plate 2-1, a pre-baffle 2-2, a pre-cover plate 2-3, a pre-pressing plate 2-4 and a pre-side plate 2-5; the pre-bottom plate 2-1 includes a pre-upper plate 2-11 and a pre-lower plate 2-12, the pre-upper plate 2-11 is a semi-cylindrical shape, the pre-lower plate 2-12 is a semi-circular shape, the pre-side plate 2-5 is a semi-circular arc plate, the radius of the pre-lower plate 2-12 is greater than the radius of the pre-upper plate 2-11, the upper surface of the circular arc of the pre-lower plate 2-12 is connected with the pre-side plate 2-5, the outer side of the diameter of the pre-lower plate 2-12 is connected with the pre-baffle 2-2, the left segment and the right segment of the pre-baffle 2-2 are both connected with a pre-pressing plate 2-4, the upper surface of the pre-lower plate 2-12 is connected with the pre-cover plate 2-3 through the pre-upper plate 2-11, and the pre-upper plate 2-11 is located between the pre-side plate 2-5 and the pre-baffle 2-2.

[0058] The pre-forming device 2 is assembled by the pre-bottom plate 2-1, the pre-stop plate 2-2, the pre-cover plate 2-3, the pre-pressing plate 2-4 and the pre-side plate 2-5, and a single-coil-shaped cavity is formed in the pre-forming device 2; wherein the pre-top plate 2-11 is a semi-cylindrical plate, the pre-bottom plate 2-12 is a semi-circular plate and the pre-side plate 2-5 is a semi-circular arc plate, and when assembled, a semi-circular arc cavity is formed between the pre-top plate 2-11 and the pre-side plate 2-5, which is convenient for placing the single-coil-shaped wire.

[0059] Preferably, the pre-bottom plate 2-1 is an integrated structure; the structure is simple and stable, and is convenient for installation.

[0060] Preferably, the pre-cover plate 2-3 comprises an upper cover plate 2-31 and a lower cover plate 2-32, the upper cover plate 2-31 is connected to the lower cover plate 2-32, the shape of the upper cover plate 2-31 is a semi-circle, the shape of the lower cover plate 2-32 is a semi-circular arc, and the radius of the upper cover plate 2-31 is greater than the radius of the lower cover plate 2-32.

[0061] By setting the upper cover plate 2-31 as a semi-circle, the pre-top plate 2-11 and the pre-side plate 2-5 are tightly covered, and since the radius of the upper cover plate 2-31 is greater than the radius of the lower cover plate 2-32 and the shape of the lower cover plate 2-32 is a semi-circular arc, when combined, the lower cover plate 2-32 is clamped into the semi-circular arc cavity between the pre-top plate 2-11 and the pre-side plate 2-5, which can not only press the coil in the semi-circular arc cavity, but also can limit the movement of the pre-cover plate 2-3.

[0062] Preferably, the pre-stop plate 2-2 comprises a first stop plate 2-21, a second stop plate 2-22 and a third stop plate 2-23, the first stop plate 2-21, the second stop plate 2-22 and the third stop plate 2-23 are vertically arranged and sequentially connected from back to front, the upper middle part of the first stop plate 2-21 is a first protrusion, the first protrusion and the third stop plate 2-23 are the same shape and symmetrically arranged front and back with the second stop plate 2-22 as the center, the shapes of the first protrusion, the second stop plate 2-22 and the third stop plate 2-23 are all arches, the lower surface of the second stop plate 2-22 and the lower surface of the first stop plate 2-21 are on the same horizontal plane, and the arc surface of the second stop plate 2-22 is lower than the arc surface of the third stop plate 2-23.

[0063] The structure makes it convenient to place the coil between the first stop plate 2-21 and the third stop plate 2-23, and the shapes of the first protrusion, the second stop plate 2-22 and the third stop plate 2-23 are all arches, so that the placed coil is pre-pressed into the required arc shape; the left end and the right end of the first stop plate 2-21 are convenient for connecting the pre-pressing plate 2-4.

[0064] Preferably, the pre-stop plate 2-2 left segment connected pre-pressing plate 2-4 includes the upper pressing plate 2-41 and the lower pressing plate 2-42, the lower middle of the upper pressing plate 2-41 is connected with the lower pressing plate 2-42, the lower pressing plate 2-42 is arc-shaped, and the left side of the lower part of the upper pressing plate 2-41 protrudes to the left.

[0065] The arc-shaped lower pressing plate 2-42 ensures that the pressed coil is arc-shaped, and the left protrusion facilitates the connection of the pre-lateral plate 2-5.

[0066] Preferably, the pre-base plate 2-1, the pre-stop plate 2-2, the pre-cover plate 2-3, the pre-pressing plate 2-4 and the pre-lateral plate 2-5 are detachably connected, and the detachable connection adopts threaded nut connection. The installation and disassembly are convenient.

[0067] Specifically, the upper surface of the pre-upper plate 2-11, the upper surface of the pre-lower plate 2-12 outside the pre-upper plate 2-11, the upper surface of the pre-lateral plate 2-5, the upper cover plate 2-31, the left and right ends of the first stop plate 2-21 and the left protrusion of the upper pressing plate 2-41 are all provided with threaded holes, and the threaded holes are matched with nuts to be combined and connected.

[0068] The working principle of the pre-forming device of the application is as follows:

[0069] Half of the single group of coils in the coil is loaded into the semicircular cavity between the pre-upper plate 2-11 and the pre-lateral plate 2-5, and the other half is loaded into the space between the first stop plate 2-21 and the third stop plate 2-23, so that the half and the other half of the single group of coils are perpendicular, the surface of the single group of coils is coated with glue, the pre-base plate 2-1, the pre-stop plate 2-2, the pre-cover plate 2-3, the pre-pressing plate 2-4 and the pre-lateral plate 2-5 are combined and fastened, the single group of coils coated with glue is pressed tightly, then the single group of coils is shaped at room temperature, the pre-forming device 2 is disassembled, the shaped coil is taken out, and the pre-forming of the single group of coils is completed.

[0070] Example 4:

[0071] Based on example 3, a forming device, the forming device 3 includes a base 4, a support seat 5, a support frame 6, a positioning frame 7, a positioning ring 8 and a top cover 9, the base 4, the support seat 5, the support frame 6, the positioning frame 7, the positioning ring 8 and the top cover 9 are connected in sequence from bottom to top.

[0072] Preferably, the support frame 6 includes two support plates 6-1, the middle parts of the two support plates 6-1 are connected perpendicularly to each other, the support plate 6-1 is arc-shaped, and the straight line surface of the arc-shaped support plate 6-1 is connected with the support seat 5.

[0073] The middle parts of the two support plates (6-1) of the support frame 6 are connected perpendicularly to each other (cross type), and the support plate 6-1 is arc-shaped, and the straight line surface of the arc-shaped support plate 6-1 is connected with the support seat 5, so that the center "cross" of the support frame 6 is completely matched with the inner circle of the coil, and the stability of the size of the coil during disassembly is ensured.

[0074] Preferably, the cross-shaped spherical center height formed by the two supporting plates 6-1 includes two sizes of (7±0.05) mm for forming and (32±0.05) mm for disassembling. When the height of the support frame 6 is increased, the support frame 6 will push the coil out of the cross-shaped slot of the positioning frame 7. Since the center "cross" of the support frame 6 is completely fitted with the inner circle of the coil, the stability of the size of the coil during disassembly is ensured.

[0075] Preferably, the positioning frame 7 includes a frame bottom 7-1 and a center body 7-2. The frame bottom 7-1 is a circular ring, and the inner circle of the circular ring is tangent to the bottom of the center body 7-2. The lower part of the center body 7-2 is a cylinder, the upper part of the center body 7-2 is a hemisphere, and a cross-shaped slot is formed in the center axis of the center body 7-2.

[0076] The support frame 6 is a "cross" shape, and the center "cross" is the supporting surface of the inner spherical surface of the coil. The center "cross" is combined and assembled with the cross-shaped slot (the width of the center "cross") of the positioning frame 7 to form a skeleton cavity base surface. The cross-shaped slot controls the "cross" width of the coil. In order to prevent the coil from rebounding in size after forming, the width is designed to be 9.9 mm, which is 0.1 mm smaller than the required range of the coil. The outer circle size of the positioning frame 7 controls the inner circle diameter Φ101 mm of the coil to form a bottom side cavity base surface. The specific size can also be designed according to the specific requirements.

[0077] Preferably, the positioning ring 8 is in the shape of a circular ring. The outer circle of the circular ring is convenient for connecting the frame bottom 7-1, and the inner circle of the circular ring is convenient for the center body 7-2 to pass through.

[0078] Preferably, the outer side of the outer circle of the positioning ring 8 is circumferentially provided with a boss, the outer side of the upper surface of the frame bottom 7-1 is circumferentially provided with a recess, and the boss and the recess are matched and connected. The boss and the recess are matched and connected, and the positioning ring 8 is concentric with the positioning frame 7 after assembly. When the boss and the recess are matched and connected, the fitting tolerance is H8 / f7, and the inner circle of the positioning ring 8 controls the outer circle diameter Φ107 mm of the coil.

[0079] Preferably, the top cover 9 is in the shape of a circular ring, the inner circle of the circular ring is provided with a cross-shaped plate, and the outer circle left side and the right side of the circular ring are both provided with a handrail 9-1. The cross-shaped plate of the top cover 9 is convenient for clamping the cross-shaped slot of the center body 7-2. The handrail 9-1 is in the shape of a U type, the opening end of the U type is connected to the outer side of the circular ring, and the structure is simple and convenient for personnel to operate.

[0080] Preferably, the bottom surface of the cross-shaped plate of the top cover 9 is a hemispherical surface. When the hemispherical surface clamps the cross-shaped slot of the center body 7-2, it ensures that the coil in the cross-shaped slot is formed into a hemispherical surface.

[0081] Preferably, the bottom surface of the top cover 9 is provided with a circular ring-shaped clamping table 9-2, and the outer diameter of the circular ring-shaped clamping table 9-2 is smaller than the inner circle diameter of the positioning ring 8.

[0082] When combined, the clamping table 9-2 is clamped to the inner circle of the positioning ring 8, and the clamping table 9-2 plays a role of positioning and limiting, facilitating the combined connection of the top cover 9 and the positioning ring 8.

[0083] Preferably, the base 4, the support seat 5, the rack bottom 7-1, the positioning ring 8 and the top cover 9 are all circumferentially provided with a plurality of threaded holes, and the threaded holes are combined and connected with nuts, facilitating installation and disassembly.

[0084] The working principle of the forming device is as follows:

[0085] Two pairs of four groups of preformed single-coil are loaded into the cross-shaped grooves of the positioning rack 7, and the coil bottom circle is completely pressed into the cavity inside the forming device along the inner circle of the positioning ring 8. The cross-shaped plate of the top cover 9 is aligned with the cross-shaped groove of the positioning rack 7, and after the top cover 9 is combined with the positioning ring 8, the top cover 9 is vertically pressed until there is no gap between the top cover 9 and the positioning ring 8, ensuring that the forming device is completely fastened. When disassembling, the top cover 9, the base 4, the positioning ring 8, the support seat 5 and the support rack 6 are sequentially removed, a disassembling support rack is replaced, the disassembling support rack is loaded into the cross-shaped groove of the positioning rack 7, the positioning rack 7 is pressed tightly with the support seat 5, and after the front hemispherical surface of the disassembling support rack is completely attached to the inner hemispherical surface of the coil in the cross-shaped groove of the positioning rack 7, the coil is integrally ejected from the cross-shaped groove of the positioning rack 7, avoiding size deformation caused by uneven force during disassembly.

[0086] Example 5:

[0087] On the basis of example 4, a single-coil winding method is provided. The winding device is installed on a winding machine, the winding tension is set to (1.1±0.1) N, the wire arrangement width is 6 mm, the winding speed is 1200 r / min, the wire is arranged along the winding groove of the winding device, the winding machine is started to wind, the cotton thread is tightened after winding, the winding device is removed, and the coil is taken off, thereby completing the winding of the single-coil. In this embodiment, a general winding machine is used for winding, and the winding starting position is set to 12 mm before winding, and the number of winding turns is 120.

[0088] Example 6:

[0089] On the basis of example 5, a single-coil preforming method is provided. The wound single-coil is placed in a coil preforming device, X98-11 glue solution is coated on the surface of the coil, the single-coil is pressed tightly by the preforming device, and the single-coil is shaped by standing at room temperature for not less than 2 hours.

[0090] Example 7:

[0091] On the basis of embodiment 6, a curing molding method of a hemispherical skeleton-free coil, the inner surfaces of each part of the molding device are thinly coated with optical lubricating grease, and then assembled from bottom to top, two pairs of four groups of pre-formed single-coil are loaded into the cross-shaped slots of the positioning frame 7, and the coil bottom circle is completely pressed into the inside of the molding device cavity along the inner circle of the positioning ring 8, the cross-shaped plate of the top cover 9 is aligned with the cross-shaped slot of the positioning frame 7, and after the top cover 9 is matched with the positioning ring 8, the top cover 9 is vertically pressed until there is no gap between the top cover 9 and the positioning ring 8, and the molding device is completely fastened.

[0092] The temperature of the high-temperature oven is set to (180±2)℃, the molding device loaded with the coil is placed in the high-temperature oven, and after (2.5±0.2) hours, it is taken out and left to dry at room temperature for no less than 3 hours, so that the coil is completely cured. After the molding device returns to room temperature, it is disassembled, and the top cover 9, the base 4, the positioning ring 8, the support seat 5 and the support frame 6 are sequentially removed, the disassembly support frame is replaced, the disassembly support frame is loaded into the cross-shaped slot of the positioning frame 7, the positioning frame 7 is pressed tightly with the support seat 5, and after the front hemispherical surface of the disassembly support frame completely matches the inner hemispherical surface of the cross-shaped slot of the positioning frame 7, the coil is integrally ejected from the cross-shaped slot of the positioning frame 7, so that the size deformation caused by uneven force during disassembly is avoided.

[0093] In the description of the present application, it should be understood that if the positions or location relationships indicated by the terms "up", "down", "right" and the like are based on the positions or location relationships shown in the drawings, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, therefore the terms describing the position relationship in the drawings are only used for exemplary description, and cannot be understood as a limitation on the present application.

[0094] The above examples are only illustrative of the present application and do not constitute a limitation on the scope of protection of the present application, and any design identical or similar to the present application falls within the scope of protection of the present application.

Claims

1. A method of forming a semi-spherical, skeletonless coil, comprising: It comprises the following steps: 1) install the winding device (1) on the winding machine, set the winding parameters on the winding machine, and tie the wire in the wire tying groove (1-1) of the winding device (1); 2) start the winding machine, and after the winding machine completes the winding according to the set winding parameters, remove the winding device (1) and take out the wound coil; 3) load the single coil in the wound coil into the preforming device (2), coat glue on the surface of the loaded coil, press the single coil coated with glue through the preforming device (2), then air dry at room temperature until the coil is shaped, remove the preforming device (2), take out the shaped coil, and complete the preforming of the single coil; 4) coat lubricating grease on the inner surfaces of the components in the forming device (3), load the four preformed coils into the forming device (3) in pairs, tighten the forming device (3), and then perform high-temperature drying, after the drying is completed, air dry the forming device (3) at room temperature for a set time, remove the forming device (3), and take out the coil, which is a hemispherical non-skeleton coil; The winding device (1) comprises a winding shaft (1-2), a first sleeve (1-3), a first stop block (1-4), a baffle one (1-5), a cylindrical pin (1-6), a mandrel (1-7), a baffle two (1-8), a nut (1-9), a second sleeve (1-10), and a second stop block (1-11), the first sleeve (1-3), the first stop block (1-4), the baffle one (1-5), the mandrel (1-7), the baffle two (1-8), the second stop block (1-11), the second sleeve (1-10), and the nut (1-9) are sequentially sleeved on the outside of the winding shaft (1-2) from left to right, and the cylindrical pin (1-6) is sequentially inserted into the baffle one (1-5), the mandrel (1-7), and the baffle two (1-8); The preforming device (2) comprises a pre-bottom plate (2-1), a pre-stop plate (2-2), a pre-cover plate (2-3), a pre-pressing plate (2-4), and a pre-side plate (2-5); the pre-bottom plate (2-1) comprises a pre-upper plate (2-11) and a pre-lower plate (2-12), the pre-upper plate (2-11) is a semi-cylindrical shape, the pre-lower plate (2-12) is a semi-circular shape, the pre-side plate (2-5) is a semi-circular arc plate, the radius of the pre-lower plate (2-12) is greater than the radius of the pre-upper plate (2-11), the upper surface of the circular arc of the pre-lower plate (2-12) is connected with the pre-side plate (2-5), the outer side of the diameter of the pre-lower plate (2-12) is connected with the pre-stop plate (2-2), the left and right sections of the pre-stop plate (2-2) are both connected with a pre-pressing plate (2-4), and the upper surface of the pre-lower plate (2-12) is connected with the pre-cover plate (2-3) through the pre-upper plate (2-11), and the pre-upper plate (2-11) is located between the pre-side plate (2-5) and the pre-stop plate (2-2). The pre-baffle (2-2) comprises a first baffle (2-21), a second baffle (2-22) and a third baffle (2-23), the first baffle (2-21), the second baffle (2-22) and the third baffle (2-23) are vertically arranged, the first baffle (2-21), the second baffle (2-22) and the third baffle (2-23) are sequentially connected from back to front, the upper middle part of the first baffle (2-21) is a first protrusion, the first protrusion and the third baffle (2-23) are the same shape and symmetrically arranged front and back with the second baffle (2-22) as the center surface, the shapes of the first protrusion, the second baffle (2-22) and the third baffle (2-23) are all arc-shaped, the lower surface of the second baffle (2-22) and the lower surface of the first baffle (2-21) are located on the same horizontal plane, and the arc surface of the second baffle (2-22) is lower than the arc surface of the third baffle (2-23).

2. The method of claim 1, wherein: the semi-spherical skeletonless coil is formed by: providing a semi-spherical skeletonless coil blank; and forming the semi-spherical skeletonless coil blank into a semi-spherical shape. The first baffle (1-5) and the second baffle (1-8) are the same shape and symmetrically distributed left and right with the mandrel (1-7) as the center, a plurality of wire tying grooves (1-1) are formed on the first baffle (1-5) and the plurality of wire tying grooves (1-1) are symmetrically distributed along the circumference.

3. The method of claim 1, wherein: the semi-spherical skeletonless coil is formed by: providing a semi-spherical skeletonless coil blank; and forming the semi-spherical skeletonless coil blank into a semi-spherical shape. The pre-cover plate (2-3) comprises an upper cover plate (2-31) and a lower cover plate (2-32), the upper cover plate (2-31) is connected to the lower cover plate (2-32), the shape of the upper cover plate (2-31) is semicircular, the shape of the lower cover plate (2-32) is semicircular arc, and the radius of the upper cover plate (2-31) is greater than the radius of the lower cover plate (2-32).

4. The method of claim 1, wherein: the semi-spherical skeletonless coil is formed by: providing a semi-spherical skeletonless coil blank; and forming the semi-spherical skeletonless coil blank into a semi-spherical shape. The pre-pressing plate (2-4) connected to the left segment of the pre-baffle (2-2) comprises a pressing upper plate (2-41) and a pressing lower plate (2-42), the lower middle part of the pressing upper plate (2-41) is connected to the pressing lower plate (2-42), the pressing lower plate (2-42) is arc-shaped, and the lower left side of the pressing upper plate (2-41) protrudes to the left.

5. The method of claim 1, wherein: the semi-spherical skeletonless coil is formed by: providing a semi-spherical skeletonless coil blank; and forming the semi-spherical skeletonless coil blank into a semi-spherical shape. The forming device (3) comprises a base (4), a support seat (5), a support frame (6), a positioning frame (7), a positioning ring (8) and a top cover (9), which are sequentially connected from bottom to top.

6. The method of forming a half-hemispherical skeletonless coil according to claim 5, wherein: The support frame (6) comprises two support plates (6-1), the middle parts of the two support plates (6-1) are connected to each other perpendicularly, the support plates (6-1) are arc-shaped, and the linear surfaces of the arc-shaped support plates (6-1) are connected to the support seat (5).

7. The method of claim 6, wherein the semi-spherical skeletonless coil forming method is characterized by: The positioning frame (7) comprises a frame bottom (7-1) and a center body (7-2), the frame bottom (7-1) is circular ring-shaped, the inner circle of the circular ring-shaped frame bottom (7-1) is tangent to the bottom of the center body (7-2), the lower part of the center body (7-2) is a cylinder, the upper part of the center body (7-2) is a hemisphere, and a cross-shaped groove is formed in the center axis of the center body (7-2) upward.

Images