A multi-layered rectangular coil winding method and a winding mold

Abstract

The application discloses a multi-layer shuttle coil winding method and a winding mold. The multi-layer shuttle coil is wound by using the winding mold with a spiral transposition step. The starting lead head is transposed from the inner circle to the outer circle through interlayer transposition, so that the starting lead head and the ending lead head of the multi-layer shuttle coil are located at the outer circle of the multi-layer shuttle coil. The multi-layer shuttle coil winding method increases the ventilation gap in the multi-layer shuttle coil, meets the heat dissipation requirement of the self-ventilation motor, and facilitates the operation during the butt welding between the shuttle coils of the self-ventilation motor.

Description

Technical Field

[0001] This invention relates to the field of self-ventilated motor manufacturing technology, specifically to a method for winding multi-layer shuttle-shaped coils and a winding mold. Background Technology

[0002] Self-ventilated motors have air ducts in the core yoke, allowing cooling air to flow through the motor's interior for cooling. The coil is the primary heat-generating component; to improve ventilation and heat dissipation, it's necessary to increase the gap between the coil and the slot. If the starting lead of the coil can be moved to the outer coil, it not only facilitates coil joint soldering but also prevents the coil from becoming too densely packed during the relocation process, thus promoting ventilation and heat dissipation.

[0003] In the manufacturing process of self-ventilated motors, a pre-formed coil must first be wound. Traditional pre-formed coils, during shuttle-shaped winding, can only be wound layer by layer, without the possibility of transposing between layers. This results in the coil's two leads exiting from one inside and one outside. Consequently, this traditional coil structure cannot meet the heat dissipation requirements of self-ventilated motors. Addressing this technical problem, a novel method for winding multi-layer shuttle-shaped coils that ensures both leads exit from the outside is a pressing technical issue that needs to be resolved.

[0004] According to the patent search, the following patents are mainly related to this application:

[0005] 1. Chinese invention patent application number "202010068706.7", application date "2020.01.21", publication number "CN111146914A", publication date "2020.05.12", titled "A Double Coil Winding Machine", applied for by "Zhejiang Juli Electric Complete Equipment Co., Ltd". This invention patent discloses a double coil winding machine, including a frame, a clamping device, a spindle device, and a wire frame structure. The clamping device and the spindle device are mounted on the frame. The wire frame structure is located outside the frame and feeds wire into the frame. The spindle device works in conjunction with the clamping device. This equipment adopts an automated working method, reducing the tediousness of manual wire changing, lowering labor costs, and improving the quality and efficiency of winding. At the same time, it allows users to independently select the wire diameter of the upper and lower layers of the coil to meet diverse customer needs, increasing the overall working range of the equipment and improving its reliability. This patent solves the technical problem of forming a double-layer coil with two wire diameters, but does not involve the technical problem of transposition between layers, and cannot transpose the inner wire end to the outer wire.

[0006] 2. A utility model patent with application number "202021395071.3", application date "2020.07.14", publication number "CN212392786U", publication date "2021.01.22", titled "A Motor Coil Winding Mold", and applicant "Wuxi Weierda Automation Machinery Co., Ltd.", relates to a motor coil winding mold, which includes: a support assembly, the support assembly including a mounting plate, a plurality of mounting holes formed on the mounting plate and spaced apart, and a... A support platform is placed on the upper surface of the mounting plate, and the circumferential surface of the mounting plate has two opposing limiting planes; a winding assembly includes multiple sets of winding rods arranged in a circle on the upper surface of the support platform, and a limiting sleeve disposed on the support platform and penetrated by the multiple sets of winding rods; the multiple sets of winding rods are spaced apart, each set of winding rods includes a first winding rod mounted on the upper surface of the support platform and perpendicular to it, and a second winding rod mounted on the free end of the first winding rod, the second winding rod having a convex arc-shaped outer end. This patent does not address the technical issue of interlayer transposition, and cannot transpose the inner wire end to the outer wire outlet.

[0007] 3. A utility model patent with application number "CN97226034.X", application date "September 11, 1997", titled "Winding Mold Structure for Motor Stator", and applicant "Wang Wenliang", describes a winding mold structure mainly composed of a wire inlet head, a telescopic fixing head, a body, a compression spring, a fixing block, a ball bearing, a shaft, a nut, a ceramic sleeve, a stop screw, a wire outlet rod, and a hexagonal sleeve bolt. Its key feature is a telescopic fixing head inside the wire inlet head. Through the action of the compression spring, the telescopic fixing head can move forward and backward within the wire inlet head. Combined with the ball screw driving the stator, this allows the stator to move forward and backward, resulting in a more even coil distribution during winding and easier wire entry. However, this patent does not address the technical issue of layer transposition; it cannot transpose the inner wire inlet head to the outer wire outlet head. Summary of the Invention

[0008] The technical problem to be solved by the present invention is to provide a method for winding multi-layer shuttle-shaped coils and a winding mold, which addresses the deficiencies in the existing technology.

[0009] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a method for winding a multi-layer shuttle-shaped coil. After the multi-layer shuttle-shaped coil is wound, the starting lead is moved from the inner coil to the outer coil by interlayer transposition, so that both the starting and ending leads of the multi-layer shuttle-shaped coil are located on the outer coil. This increases the ventilation gap within the multi-layer shuttle-shaped coil, meeting the heat dissipation requirements of a self-ventilated motor; it also facilitates the parallel welding operation between the shuttle-shaped coils of the self-ventilated motor.

[0010] Furthermore, the interlayer transposition is achieved by increasing the winding size of the first turn where the starting lead is located, so that the wound first turn can be pushed onto the second outer turn of the multi-layer spindle coil, thereby enabling the starting lead to be transposed from the inner turn to the outer turn of the multi-layer spindle coil.

[0011] Furthermore, by setting a spiral transposition step on the winding die that is higher than the winding surface, the winding size of the first turn is increased. The starting lead is first wound on the spiral transposition step. After the multi-layer shuttle coil is wound, the starting lead is pushed onto the second outer turn of the wound multi-layer shuttle coil along the axial direction of the winding die.

[0012] The above-mentioned method for winding multi-layer shuttle-shaped coils includes the following steps:

[0013] S1: Load the winding die into the winding machine, and then install the lifting core onto the winding die;

[0014] S2: Fix the starting lead of the coil onto the spiral transposition step of the winding mold, rotate the winding machine or coil, and start from the spiral transposition step, move the coil away from the spiral transposition step to wind the first layer of coil.

[0015] S3: Change the direction of the coil movement, wind the coil onto the lifting mold core, and then move the coil toward the direction of the spiral transposition step. Wind the second layer of coil on top of the first layer of coil. When winding close to the spiral transposition step, change the direction of the coil movement again and wind more layers of coil in sequence.

[0016] S4: When winding the outermost coil, leave a space of no less than one coil width near the spiral transposition step. Along the axis of the winding mold, push the starting lead of the coil from the spiral transposition step to the second outermost coil, so that the starting lead of the coil is close to the ending lead of the coil, thereby transposing the starting lead of the coil to the outer ring of the multi-layer shuttle coil.

[0017] S5: Along the axial direction of the winding die, remove the lifting die core from the winding die, then remove the wound multi-layer shuttle coil from the winding die and tie it with binding wire.

[0018] This invention also discloses a winding mold for implementing the above-described multi-layer shuttle coil winding method: the winding mold has an elliptical cross-section, the outer circumferential surface of the ellipse is the winding surface, and one end of the winding mold is provided with a spiral transposition step. The spiral transposition step is used to increase the winding size of the first turn, so that the wound first turn can be pushed onto the second outer turn of the multi-layer shuttle coil, thereby allowing the starting lead to be transposed from the inner turn to the outer turn of the multi-layer shuttle coil.

[0019] Furthermore, the initial height of the transposition step above the winding surface is not less than the thickness of the coil; the height of the transposition step gradually decreases along the spiral, falling to the winding surface within one turn. This is so that the inner coil size of the first turn after winding is sufficiently larger than the outer coil size of the second outer coil, allowing the first turn after winding to be smoothly pushed onto the second outer coil of the multilayer shuttle coil.

[0020] Furthermore, the initial height of the transposition step is greater than or equal to the thickness of the wire turns multiplied by the number of coil layers.

[0021] Furthermore, a lifting die core is detachably installed on the outer side of the spiral transposition step. The lifting die core can slide along the axial direction of the winding die on the winding die to assist the wire turns in winding onto the pre-wound coil, so that multi-layered spindle-shaped coils can be wound smoothly.

[0022] Furthermore, the lifting die core includes: a lifting baffle, an annular guide plate, and a mounting plate. The annular guide plate is higher than or equal to the winding surface thickness multiplied by the number of coil layers. The mounting plate is located on the other side of the lifting baffle and has screw holes. Bolts are used to install the mounting plate onto the other end of the winding die. By moving and adjusting the axial position of the lifting die core on the winding die, the number of turns per layer can be controlled. By moving and adjusting the height of the annular guide plate above the winding surface, the number of layers of the shuttle-shaped coil can be controlled.

[0023] Furthermore, it also includes auxiliary molds, which are installed on the same straight line on the winding machine, spaced apart from the winding molds. The coils are wound sequentially between the winding molds and the auxiliary molds, forming multi-layered shuttle-shaped coils. By adjusting the distance between the winding molds and the auxiliary molds, various shuttle-shaped coils with different inner coil sizes can be wound using the same set of molds. This improves the utilization rate of the winding molds, reduces the types and number of winding molds, and lowers production costs.

[0024] The beneficial effects of this invention are as follows: A multi-layer shuttle-shaped coil is wound using a winding mold with spiral transposition steps. By transposing the coil between layers, the starting lead is moved from the inner coil to the outer coil, ensuring that both the starting and ending leads of the multi-layer shuttle-shaped coil are located on the outer coil. This multi-layer shuttle-shaped coil winding method increases the ventilation gap within the coil, meeting the heat dissipation requirements of a self-ventilated motor; it also facilitates the parallel welding operation between shuttle-shaped coils in a self-ventilated motor. Attached Figure Description

[0025] Figure 1 This is a 3D schematic diagram of a winding mold.

[0026] Figure 2 This is a cross-sectional view of the winding die.

[0027] Figure 3 This is a three-dimensional schematic diagram of the lifting mold core.

[0028] Figure 4 This is a cross-sectional view of the riser mold core.

[0029] Figure 5 A three-dimensional schematic diagram of the riser core assembled into the winding die.

[0030] Figure 6 A cross-sectional view showing the assembly of the auxiliary mold core into the winding mold.

[0031] Figure 7 This is a schematic diagram of Example 1 during the first winding.

[0032] Figure 8 This is a schematic diagram of Example 1 when winding the second turn.

[0033] Figure 9 This is a schematic diagram of Example 1 when the third turn is wound.

[0034] Figure 10 This is a schematic diagram of Example 1 when the fourth turn is wound.

[0035] Figure 11 This is a schematic diagram of the fifth turn of the winding process using a multilayer mold core in Example 1.

[0036] Figure 12 This is a schematic diagram of Example 1 when the 6th turn is wound.

[0037] Figure 13 This is a schematic diagram showing the result after the starting lead head is swapped in Example 1.

[0038] Figure 14 This is a schematic diagram of the lifting mold core after it has been removed in Example 1.

[0039] Figure 15 This is a schematic diagram of Example 2 during the first winding.

[0040] Figure 16 This is a schematic diagram of Example 2 when winding the second turn.

[0041] Figure 17 This is a schematic diagram of Example 2 when winding the third turn.

[0042] Figure 18 This is a schematic diagram of Example 2 when the fourth turn is wound.

[0043] Figure 19 This is a schematic diagram of the fifth turn of the winding process using a multilayer mold core in Example 2.

[0044] Figure 20 This is a schematic diagram of Example 2 when the 6th turn is wound.

[0045] Figure 21 This is a schematic diagram showing the result after the starting lead head has been swapped in Example 2.

[0046] Figure 22 This is a schematic diagram of the lifting mold core after it has been removed in Example 2.

[0047] In the diagram: 1—winding mold, 11—mold baffle, 12—spiral transposition step, 13—winding surface, 14—mounting hole, 2—lifting core, 21—lifting baffle, 22—annular guide plate, 23—mounting plate, 3—wire turn, 4—auxiliary mold, h—wire turn thickness, n—number of coil layers, Q1—1st turn, Q2—2nd turn, Q3—3rd turn, Q4—4th turn, Q5—5th turn, Q6—6th turn, H—initial height of transposition step, V—wire turn movement direction, Z—winding mold axial direction. Detailed Implementation

[0048] The present invention will be further described below with reference to specific embodiments and accompanying drawings:

[0049] The winding die 1 of the present invention is as follows Figure 1 and 2 As shown, the system includes: a mold baffle 11, a spiral transposition step 12, and a winding surface 13. The winding mold 1 is an elliptical cylinder, and the outer circumference of the elliptical cylinder of the winding mold 1 is the winding surface 13 used to wind the multi-layer shuttle coil. A mold baffle 11, exceeding the outer circle size of the multi-layer shuttle coil, is provided at one end of the elliptical cylinder to control the winding range of the multi-layer shuttle coil. A spiral transposition step 12 is provided near the mold baffle 11, and the spiral transposition step 12 is higher than the winding surface 13. The initial height H of the transposition step is greater than or equal to the coil thickness h × the number of coil layers (n-1). The height H of the transposition step gradually decreases along the spiral, falling to the winding surface 13 within one turn. This ensures that the inner circle size of the first turn after the multi-layer shuttle coil is wound is sufficiently larger than the outer circle size of the second outermost turn, allowing the first turn to be smoothly pushed onto the second outermost turn of the multi-layer shuttle coil. The second outermost turn is the innermost turn of the outermost multi-layer shuttle coil.

[0050] The lifting mold core 2 of the present invention is as follows Figure 3 and 4 As shown, the device includes: a lifting baffle 21, an annular guide plate 22, and a mounting plate 23. The lifting baffle 21 extends beyond the outer diameter of the multi-layer shuttle coil, and is used to control the winding range of the multi-layer shuttle coil. An annular guide plate 22 is provided on one side of the lifting baffle 21, and a mounting plate 23 is provided on the other side. The mounting plate 23 has screw holes, and bolts are used to mount the mounting plate 23 to the other end of the winding mold 1.

[0051] After the lifting core 2 is installed onto the winding die 1, as follows: Figure 5 and 6As shown, the annular guide plate 22 extends above the winding surface 13. The height of the annular guide plate 22 above the winding surface 13 is greater than or equal to the coil thickness h × the number of coil layers (n-1). By moving and adjusting the axial position of the lifting die core 2 on the winding die 1, the number of turns wound in each layer can be controlled; by moving and adjusting the height of the annular guide plate 22 above the winding surface 13, the number of layers of the shuttle-shaped coil can be controlled.

[0052] Example 1 of the multilayer shuttle-shaped coil winding method of the present invention is as follows: Figures 7 to 14 As shown, it includes the following steps:

[0053] Step 1 as follows Figure 7 As shown: The winding mold 1 is loaded into the winding machine, and then the lifting mold core 2 is installed on the winding mold 1;

[0054] Step Two Figures 7 to 10 As shown: Fix the starting lead of the coil 3 on the spiral transposition step 12 of the winding mold 1, rotate the winding machine or the coil 3, and start from the spiral transposition step 12 to move the coil 3 away from the spiral transposition step 12 to wind the first layer of coil.

[0055] Step 3 as follows Figures 10 to 12 As shown: Change the direction of the coil 3, wind the coil 3 onto the lifting mold core 2, and then move the coil 3 toward the spiral transposition step 12. Wind the second layer of coil on top of the first layer of coil. When the coil is close to the spiral transposition step 12, change the direction of the coil 3 again and wind more layers of coil in sequence.

[0056] Step four as follows Figures 12 to 13 As shown: When winding the outermost coil, leave a space of no less than the width of one coil 3 near the spiral transposition step 12. Along the Z-axis of the winding mold, push the starting lead of coil 3 from the spiral transposition step 12 onto the next outermost coil, so that the starting lead of coil 3 is close to the ending lead of coil, thereby transposing the starting lead of coil 3 to the outer ring of the multi-layer shuttle coil.

[0057] Step 5 Figures 13 to 14 As shown: Along the Z-axis of the winding mold, the lifting core 2 is removed from the winding mold 1, and then the wound multi-layer shuttle coil is removed from the winding mold 1 and tied and fixed with binding wire.

[0058] Example 2 of the multilayer shuttle-shaped coil winding method of the present invention is as follows: Figures 15 to 22As shown, in embodiment 2, an auxiliary mold 4 is also provided. The auxiliary mold 4 and the winding mold 1 are installed on the same straight line on the winding machine, spaced apart. The coil 3 is wound sequentially between the winding mold 1 and the auxiliary mold 4, forming a multi-layered shuttle-shaped coil on the winding mold 1 and the auxiliary mold 4. By adjusting the distance between the winding mold 1 and the auxiliary mold 4, various shuttle-shaped coils with different inner coil sizes can be wound using the same set of molds. This improves the utilization rate of the winding mold 1, reduces the types and number of winding molds, and lowers production costs.

[0059] In summary, the beneficial effects of this invention are as follows: A multi-layer shuttle-shaped coil is wound using a winding mold with spiral transposition steps. By transposing the starting lead from the inner coil to the outer coil, both the starting and ending leads of the multi-layer shuttle-shaped coil are located on the outer coil. This multi-layer shuttle-shaped coil winding method increases the ventilation gap within the coil, meeting the heat dissipation requirements of a self-ventilated motor; it also facilitates the parallel welding operation between shuttle-shaped coils in a self-ventilated motor.

[0060] The above embodiments are for illustrative purposes only and are not intended to limit the invention. Those skilled in the art can make various changes or modifications without departing from the spirit and scope of the invention. Therefore, all equivalent technical solutions should also fall within the protection scope of the invention, which should be defined by the claims.

Claims

1. A method for winding a multi-layer shuttle-shaped coil, characterized in that: The winding size of the first turn is increased by setting a spiral transposition step (12) that is higher than the winding surface on the winding mold (1). The starting lead is first wound on the spiral transposition step (12) so that the first turn after winding can be pushed onto the second outer turn of the multilayer shuttle coil. The cross-section of the winding mold (1) is elliptical, and the outer circumferential surface of the ellipse is the winding surface (13). A spiral transposition step (12) is set at one end of the winding mold (1). The spiral transposition step (12) is higher than the transposition step of the winding surface (13). The initial height (H) is not less than the coil thickness (h); the transposition step height (H) gradually decreases along the spiral, dropping to the winding surface (13) within one turn; after the multi-layer shuttle coil is wound, the starting lead is pushed onto the outermost ring of the wound multi-layer shuttle coil along the winding die axis; by interlayer transposition, the starting lead is transposed from the inner ring to the outer ring, so that the starting lead and the ending lead of the multi-layer shuttle coil are both on the outer ring of the multi-layer shuttle coil; the multi-layer shuttle coil winding method includes the following steps: S1: Load the winding die into the winding machine, and then install the lifting core onto the winding die; S2: Fix the starting lead of the coil onto the spiral transposition step of the winding mold, rotate the winding machine or coil, and start from the spiral transposition step, move the coil away from the spiral transposition step to wind the first layer of coil. S3: Change the direction of the coil movement, wind the coil onto the lifting mold core, and then move the coil toward the direction of the spiral transposition step. Wind the second layer of coil on top of the first layer of coil. When winding close to the spiral transposition step, change the direction of the coil movement again and wind more layers of coil in sequence. S4: When winding the outermost coil, leave a space of no less than one coil width near the spiral transposition step. Along the axis of the winding mold, push the starting lead of the coil from the spiral transposition step to the second outermost coil, so that the starting lead of the coil is close to the ending lead of the coil, thereby transposing the starting lead of the coil to the outer ring of the multi-layer shuttle coil. S5: Along the axial direction of the winding die, remove the lifting die core from the winding die, then remove the wound multi-layer shuttle coil from the winding die and tie it with binding wire.

2. The method for winding multi-layer shuttle-shaped coils according to claim 1, characterized in that: The initial height (H) of the transposition step is greater than or equal to the thickness of the coil turns (h) × the number of coil layers (n-1).

3. The method for winding multi-layer shuttle-shaped coils according to claim 2, characterized in that: The outer side of the spiral transposition step (12) is detachably equipped with a lifting mold core (2), which can slide on the winding mold (1) along the winding mold axis (Z) to assist the wire turn (3) to be wound onto the already wound coil.

4. The method for winding multi-layer shuttle-shaped coils according to claim 3, characterized in that: The lifting mold core (2) includes: lifting baffle (21), annular guide plate (22) and mounting plate (23). The height of the annular guide plate (22) above the winding surface (13) is greater than or equal to the thickness of the coil (h) × the number of coil layers (n-1). The mounting plate (23) is set on the other side of the lifting baffle (21). The mounting plate (23) is provided with screw holes. The mounting plate (23) is installed on the other end of the winding mold (1) by bolts.

5. The method for winding a multi-layer shuttle-shaped coil according to any one of claims 1 to 4, characterized in that: It also includes an auxiliary mold (4), which is installed on the same straight line on the winding machine as the winding mold (1). The wire turns (3) are wound sequentially between the winding mold (1) and the auxiliary mold (4) to form a multi-layer shuttle coil.

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