A winding device for an electric generator armature

Abstract

The application provides a winding device for a generator armature, which comprises a needle nozzle rod mechanism and a jig rotating positioning mechanism, the needle nozzle rod mechanism is installed above the jig rotating positioning mechanism, a winding needle nozzle is installed on the needle nozzle rod mechanism, a plurality of winding columns are annularly distributed on the jig rotating positioning mechanism, and a slot outer wire arranging and hanging mechanism is further installed above the jig rotating positioning mechanism, and the slot outer wire arranging and hanging mechanism and the needle nozzle rod mechanism cooperatively move to complete winding on the winding columns. The application can realize that a plurality of wires pass through a narrow slot, realize a winding mechanism with high slot fullness, and especially realize automatic winding of an armature with high slot fullness, multi-wire parallel winding and extremely narrow slot.

Description

Technical Field

[0001] This invention relates to a winding device for generator armatures, belonging to the technical field of automatic winding equipment for motor armatures. Background Technology

[0002] Currently, winding mechanisms are mainly based on manual winding, resulting in low consistency and efficiency. For example, Chinese Patent No. CN114552917A discloses an automatic winding device for motor stators, and Chinese Patent No. CN217307507U discloses a stator winding guide needle flipping mechanism. Both can only perform automatic winding by inserting needles into slots within a certain slot fill factor and slot width. Therefore, the needle insertion method determines that the armature slot fill factor cannot be too high, multiple strands cannot be wound together, and the slot opening is extremely narrow, making it impossible to achieve high slot fill factor armature winding. Summary of the Invention

[0003] To solve the above-mentioned technical problems, the present invention provides a winding device for generator armature, wherein the needle of the winding device for generator armature does not enter the slot, and a winding mechanism that enables multiple strands of wire to pass through a narrow slot is provided, thereby solving the above problems.

[0004] The present invention is achieved through the following technical solutions.

[0005] The present invention provides a winding device for a generator armature, comprising a needle rod mechanism and a fixture rotation and positioning mechanism. The needle rod mechanism is installed directly above the fixture rotation and positioning mechanism and is equipped with a winding needle. Multiple winding posts are arranged in a ring on the fixture rotation and positioning mechanism. An external slot wire feeding and hanging mechanism is also installed above the fixture rotation and positioning mechanism. The external slot wire feeding and hanging mechanism and the needle rod mechanism work together to complete the winding of the winding posts.

[0006] The winding post has a core positioning mechanism located at the inner edge of the distribution ring.

[0007] The needle rod mechanism consists of a winding needle, a needle Z-direction motion module, a needle Y-direction motion module, and a needle X-direction motion module. The needle X-direction motion module, needle Y-direction motion module, needle Z-direction motion module, and winding needle are installed in sequence, so that the winding needle can move in three-dimensional space.

[0008] The needle nozzle Z-direction motion module has a flat plate structure with a ceramic eye vertically opened on the flat plate structure. A winding rod is vertically installed below the flat plate structure, and the winding needle nozzle is installed on the side of the bottom end of the winding rod.

[0009] A pulley is also installed on the winding rod directly below the ceramic eye.

[0010] The cable hanging mechanism outside the trough includes an upper cable hanging mechanism and a lower cable hanging mechanism. The upper and lower cable hanging mechanisms are installed symmetrically, and each of the upper and lower cable hanging mechanisms is equipped with a cable hanging post.

[0011] In a vertical projection, the orientation of the cable guide post is perpendicular to the winding needle nozzle.

[0012] The cable guide post is mounted on the cylinder, the cylinder is mounted on the drive module, and the drive module is fixed to the mounting platform.

[0013] The fixture rotation positioning mechanism is fixed to the mounting platform, and the fixture rotation positioning mechanism has a rotatable clamp; the winding post and the iron core positioning mechanism are installed on the upper surface of the clamp, and a slip ring is installed on the fixture rotation positioning mechanism at the position of the inner ring of the distribution ring of the iron core positioning mechanism.

[0014] The fixture rotation and positioning mechanism is driven to rotate by a synchronous belt mechanism fixed to the bottom of the mounting platform. The synchronous belt mechanism consists of a servo motor, a synchronous belt, and a synchronous pulley.

[0015] The beneficial effects of this invention are: it enables multiple strands of wire to pass through narrow slots, achieving a high slot fill factor winding mechanism. Attached Figure Description

[0016] Figure 1 This is a structural schematic diagram of at least one embodiment of the present invention;

[0017] Figure 2 yes Figure 1 A bottom view;

[0018] Figure 3 yes Figure 1 Schematic diagram of the needle tip rod mechanism;

[0019] Figure 4 yes Figure 1 A schematic diagram of the rotating positioning mechanism of the central fixture.

[0020] In the diagram: 1-Needle tip rod mechanism, 10-Needle tip Z-direction motion module, 101-Ceramic eye, 102-Pulley, 103-Winding needle tip, 104-Winding rod, 11-Needle tip Y-direction motion module, 12-Needle tip X-direction motion module, 2-Jig rotation positioning mechanism, 200-Winding post, 201-Iron core positioning mechanism, 202-Slip ring, 203-Clamp, 3-Upper slot outer wire feeding and hanging mechanism, 304-Wire feeding post, 4-Lower slot outer wire feeding and hanging mechanism, 5-Synchronous belt mechanism, 6-Mounting platform, 7-Iron core, 40-Drive module, 41-Cylinder, 42-Wire feeding and hanging post, 5-Synchronous belt mechanism, 50-Servo motor, 51-Synchronous belt, 52-Synchronous pulley. Detailed Implementation

[0021] The technical solution of the present invention is further described below, but the scope of protection is not limited to what is described.

[0022] Example 1

[0023] like Figures 1 to 4 The diagram shows a winding device for a generator armature, comprising a needle rod mechanism 1 and a fixture rotation and positioning mechanism 2. The needle rod mechanism 1 is mounted directly above the fixture rotation and positioning mechanism 2, and a winding needle 103 is mounted on the needle rod mechanism 1. Multiple winding posts 200 are arranged in a ring on the fixture rotation and positioning mechanism 2. An external slot wire feeding and hanging mechanism is also mounted above the fixture rotation and positioning mechanism 2. The external slot wire feeding and hanging mechanism and the needle rod mechanism 1 work together to complete the winding of the winding posts 200.

[0024] Example 2

[0025] Based on Embodiment 1, the winding post 200 has a core positioning mechanism 201 located at the inner edge of the distribution ring.

[0026] Example 3

[0027] Based on Embodiment 1, the needle rod mechanism 1 consists of a winding needle 103, a needle Z-direction motion module 10, a needle Y-direction motion module 11, and a needle X-direction motion module 12. The needle X-direction motion module 12, the needle Y-direction motion module 11, the needle Z-direction motion module 10, and the winding needle 103 are installed in sequence, so that the winding needle 103 can move in three-dimensional space.

[0028] Example 4

[0029] Based on embodiment 3, the needle nozzle Z-direction motion module 10 has a flat plate structure, a ceramic eye 101 is vertically opened on the flat plate structure, a winding rod 104 is vertically installed below the flat plate structure, and a winding needle nozzle 103 is installed on the side of the bottom end of the winding rod 104.

[0030] Example 5

[0031] Based on embodiment 4, a pulley 102 is also installed on the winding rod 104 at a position directly below the ceramic eye 101.

[0032] Example 6

[0033] Based on Embodiment 1, the cable hanging mechanism outside the trough includes an upper trough cable hanging mechanism 3 and a lower trough cable hanging mechanism 4. The upper trough cable hanging mechanism 3 and the lower trough cable hanging mechanism 4 are installed symmetrically above and below each other, and each of the upper trough cable hanging mechanism 3 and the lower trough cable hanging mechanism 4 is equipped with a cable hanging post 304.

[0034] Example 7

[0035] Based on Embodiment 1, in vertical projection, the orientation of the cable guide post 304 is perpendicular to the winding needle nozzle 103.

[0036] Example 8

[0037] Based on Embodiment 1, the cable guide post 304 is mounted on the cylinder 41, the cylinder 41 is mounted on the drive module 40, and the drive module 40 is fixed to the mounting platform 6.

[0038] Example 9

[0039] Based on Embodiment 1, the fixture rotation positioning mechanism 2 is fixed to the mounting platform 6, and the fixture rotation positioning mechanism 2 has a rotatable clamp 203; the winding post 200 and the iron core positioning mechanism 201 are installed on the upper surface of the clamp 203, and a slip ring 202 is installed on the fixture rotation positioning mechanism 2 at the position of the inner ring of the distribution ring of the iron core positioning mechanism 201.

[0040] Example 10

[0041] Based on embodiment 9, the fixture rotation positioning mechanism 2 is driven to rotate by the synchronous belt mechanism 5 fixed to the bottom of the mounting platform 6. The synchronous belt mechanism 5 consists of a servo motor 50, a synchronous belt 51, and a synchronous pulley 52.

[0042] Example 11

[0043] Based on the above embodiments, specifically, a winding device for a high slot fill factor, multi-wire parallel winding generator armature includes a jig rotation mechanism. The jig rotation mechanism includes a winding post, a positioning block, a slip ring, and a servo-driven synchronous belt mechanism. The winding post is used to install the starting wire during core winding. The positioning block provides circumferential positioning of the core's outer circumference when the core is inserted. The slip ring has a very high surface finish and is divided into two halves. The opening between the two halves aligns perfectly with the core slot after the core is inserted. The slip ring assists in inserting the enameled wire into the stator core slot. The servo-driven synchronous belt mechanism includes a servo motor, a synchronous belt, and a synchronous pulley. The servo motor drives the entire jig to rotate using the synchronous belt pulley. The core and the jig rotation mechanism have a positioning and clamping relationship. During winding, the jig rotation mechanism drives the needle assembly, which rotates the core reciprocally and moves up and down, to complete the core winding.

[0044] The needle tip rod mechanism is mounted on a three-axis mechanism capable of spatial movement. This three-axis mechanism mainly includes three sets of servo motors, a lead screw nut, a winding needle tip, and a winding rod. Its primary function is to allow the needle tip to move spatially during winding. The needle tip rod mechanism is the main path for the enameled wire, which is multi-stranded. Each strand is tensioned by a tensioner to maintain a specific tension. The needle tip rod mechanism requires the use of an external wire-laying mechanism to achieve winding without the wire entering the slot.

[0045] The external cable routing mechanism includes a single-axis module, a cylinder, and auxiliary cable routing posts. The single-axis module is a servo motor lead screw mechanism. The cylinder is mounted on the module and can move to different positions as the module moves. The auxiliary cable routing posts are mounted on the cylinder. When the needle assembly moves to the upper or lower position, the auxiliary cable routing posts act as iron core teeth, completing the cable routing. There are two sets of external cable routing fixtures, one above and one below the fixture rotation mechanism. The needle assembly and the external cable routing fixtures, together with the fixture rotation mechanism, complete the iron core winding.

[0046] The needle assembly can move in a three-axis space, with each axis movement precisely controlled by a servo motor. The winding rod is equipped with multiple ceramic eyes for threading the enameled wire to the winding needle.

[0047] The enameled wire passes through the winding needle and begins to wind onto the winding post. The fixture rotation mechanism drives the iron core to be positioned so that the first winding slot of the iron core is aligned with the slip ring. The needle assembly moves downward. During the process, the enameled wire is always under tension and is guided into the iron core slot by the slip ring.

[0048] When the needle assembly winds the wire to the bottom and moves towards the outer circle of the iron core, the external wire hanging auxiliary mechanism extends the auxiliary wire hanging post and follows it. The needle assembly continues to descend and retracts to the position where it can move upward inside the iron core hole.

[0049] The auxiliary wire hanging mechanism below the jig rotation mechanism hangs the enameled wire. When the needle assembly is ready to move upward, the jig rotation mechanism rotates by one slot angle.

[0050] As the needle assembly moves upward, the auxiliary wire hanging mechanism outside the slot retracts the auxiliary wire hanging post, and the enameled wire falls accurately onto the iron core end plate.

[0051] During operation, the winding above the iron core is completed in sequence.

[0052] The fixture rotation mechanism rotates at a certain angle, and the needle assembly works in coordination to complete the armature crossing.

[0053] Example 12

[0054] Based on the above embodiments, during use, the stator core to be wound is placed into the jig rotation positioning mechanism at a predetermined position. This "predetermined position" refers to the mating position between the positioning groove on the outer circumference of the stator core and the positioning block on the jig rotation mechanism. After the jig rotation mechanism and the core are positioned, the core will move along with the mechanism during the subsequent winding process. Because the jig rotation mechanism is driven by a servo motor and synchronous belt below, the core can rotate precisely with the jig according to the program control.

[0055] The jig rotation mechanism also features a slip ring with an opening slot the same size as the custom-made iron core. Its main function is to guide the enameled wire into the stator core slot when the needle rod mechanism moves up and down with the wire. Since the needle does not enter the stator core slot, the slip ring structure is a crucial component for achieving automatic winding.

[0056] The needle tip rod mechanism is capable of 3-axis motion. The needle rod is driven by a motor, which enables the needle tip to rotate. Small pulleys and ceramic eyes are installed on the needle tip rod for passing multiple strands of enameled wire through the needle tip rod. Here, it is assumed that each strand of enameled wire is already under tension.

[0057] The external wire-laying mechanism mainly consists of a linear module and a cylinder mounted on the linear module. The cylinder is equipped with a wire-laying post, whose main function is to assist in wire placement and laying during the winding process. Since the needle nozzle cannot enter the stator slot, an external wire-laying mechanism is needed to directly wind the coil onto the stator core teeth. Therefore, there are external wire-laying mechanisms at both ends of the stator core.

[0058] During automatic winding, the enameled wire passes through the needle rod assembly and is led out from the needle tip. With manual assistance, the enameled wire is wound onto the winding post of the jig rotation mechanism. At this time, the slip ring slot and the iron core slot are aligned. The needle rod mechanism moves downward, and multiple strands of enameled wire pass through the narrow slot of the slip ring and enter the stator iron core slot. After the needle rod reaches the first lower limit position, the slip ring opening and the needle tip are misaligned, and the needle rod mechanism moves towards the outer circle of the iron core. After moving to the outermost position, the lower wire hanging mechanism module and cylinder move to the wire hanging position and push out the wire hanging post. The needle assembly continues to move downward to the second lower limit position and then retracts towards the center of the stator iron core, returning to the position where the needle tip moves upward and just does not interfere with the slip ring. Simultaneously, the jig rotation mechanism rotates one tooth distance, and the needle rod mechanism moves upward, with the enameled wire being guided in by the slip ring.

[0059] Similarly, after the needle rod reaches the first upper limit position, the needle tip and the slip ring opening are misaligned. The needle rod mechanism moves towards the outer circle of the stator core. After reaching the outermost position, the upper wire-hanging mechanism module and cylinder move to the wire-hanging position and push out the wire-hanging post. The needle assembly continues to move upward to the second upper limit position and then retracts towards the center of the stator core, returning to a position where the needle tip moves downward and just does not interfere with the slip ring. Simultaneously, the fixture rotation mechanism rotates one tooth distance, completing one turn of winding on the stator core tooth. This cycle repeats to complete the winding of an entire armature.

[0060] Therefore, this invention mainly includes a fixture rotation mechanism, a needle tip rod mechanism, and a wire hanging and laying mechanism outside the slot. These three mechanisms cooperate according to a certain logical relationship to complete the automatic winding process where the needle tip does not enter the slot, multiple strands of wire are wound together, and the enameled wire passes through a narrow slot. The fixture rotation mechanism accurately positions the iron core and drives it to rotate accurately under the drive of a servo motor using a synchronous pulley and belt, with the help of a slip ring for wire insertion. The needle tip assembly serves as the winding guide and is mounted on a three-axis motion mechanism. The wire hanging auxiliary mechanism works in conjunction with the needle tip assembly, and the needle tip assembly and the fixture rotation mechanism cooperate to complete the automatic winding process where the needle tip does not enter the slot. This winding method makes it possible to wind armatures with high slot fill factor.

Claims

1. A winding device for a generator armature, comprising a needle rod mechanism (1) and a fixture rotation and positioning mechanism (2), characterized in that: The needle rod mechanism (1) is installed directly above the fixture rotation positioning mechanism (2). The needle rod mechanism (1) is equipped with a winding needle (103). Multiple winding posts (200) are distributed in a ring on the fixture rotation positioning mechanism (2). A slot-out wiring and hanging mechanism is also installed above the fixture rotation positioning mechanism (2). The slot-out wiring and hanging mechanism and the needle rod mechanism (1) work together to complete the winding of the winding posts (200). The needle rod mechanism (1) consists of a winding needle (103), a needle Z-direction motion module (10), a needle Y-direction motion module (11), and a needle X-direction motion module (12). The needle X-direction motion module (12), needle Y-direction motion module (11), needle Z-direction motion module (10), and winding needle (103) are installed in sequence, so that the winding needle (103) can move in three-dimensional space. The needle Z-direction motion module (10) has a flat plate structure, and a ceramic eye (101) is vertically opened on the flat plate structure. A winding rod (104) is vertically installed below the flat plate structure, and the winding needle (103) is installed on the side of the bottom end of the winding rod (104). The fixture rotation positioning mechanism (2) is fixed to the mounting platform (6), and there is a rotatable clamp (203) on the fixture rotation positioning mechanism (2); the winding post (200) and the iron core positioning mechanism (201) are installed on the upper surface of the clamp (203), and a slip ring (202) is installed on the fixture rotation positioning mechanism (2) at the position of the inner ring of the distribution ring of the iron core positioning mechanism (201); the fixture rotation positioning mechanism (2) is driven to rotate by the synchronous belt mechanism (5) fixed to the bottom of the mounting platform (6), and the synchronous belt mechanism (5) is composed of a servo motor (50), a synchronous belt (51), and a synchronous pulley (52); The slot of the slip ring (202) is aligned with the slot of the iron core (7), and the slip ring is used in conjunction with the winding needle (103), and the enameled wire is assisted in entering the wire with the help of the slip ring (202).

2. The winding device for generator armature as described in claim 1, characterized in that: The winding post (200) has a core positioning mechanism (201) located at the inner edge of the distribution ring.

3. The winding device for generator armature as described in claim 1, characterized in that: A pulley (102) is also installed on the winding rod (104) directly below the ceramic eye (101).

4. The winding device for generator armature as described in claim 1, characterized in that: The cable hanging mechanism outside the trough includes an upper cable hanging mechanism (3) and a lower cable hanging mechanism (4). The upper cable hanging mechanism (3) and the lower cable hanging mechanism (4) are installed symmetrically above and below each other. Cable hanging posts (304) are installed on the upper cable hanging mechanism (3) and the lower cable hanging mechanism (4).

5. The winding device for generator armature as described in claim 4, characterized in that: In vertical projection, the orientation of the cable guide post (304) is perpendicular to the winding needle nozzle (103).

6. The winding device for generator armature as described in claim 4, characterized in that: The cable guide post (304) is mounted on the cylinder (41), the cylinder (41) is mounted on the drive module (40), and the drive module (40) is fixed to the mounting platform (6).

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