Electromagnet winding process and device

Abstract

The application relates to an electromagnet technical field, in particular to an electromagnet winding process method and device, the electromagnet winding device comprises a rack and a tensioner frame; a large base plate is arranged at the top of the rack, tail top mechanisms, main shaft boxes, winding motors and wire arranging mechanisms are correspondingly arranged on the large base plate, the tail top mechanisms are arranged opposite to the main shaft boxes, the winding motors are connected with the main shaft boxes, a wire feeding mechanism is slidably arranged on the wire arranging mechanism, and a winding length detection mechanism is fixedly arranged on the wire feeding mechanism; a servo motor driving wire feeding tensioner is fixedly arranged at the upper end of the tensioner frame, and the enameled wire is placed at the bottom of the tensioner frame. The application has the characteristics of simple operation, convenient use and maintenance, high servo control precision, strong practicability, safety, reliability and the like; the original design state of the electromagnetic force of the electromagnet coil can be effectively recovered, the use quality is stable, and the scrapped electromagnet can be 100% reused.

Description

Technical Field

[0001] This invention relates to the field of electromagnet technology, specifically to an electromagnet winding process and apparatus. Background Technology

[0002] Electromagnets are used in aircraft solenoid valves and consist of a push rod, frame, stop block, armature, and coil, such as... Figure 1 As shown, the coil is formed by winding enameled wire into a frame. The push rod is made of a non-magnetic material (such as copper). The frame, stop, and armature are generally made of soft magnetic material (electrical pure iron DT4A), which has low coercivity and is easily magnetized. The stop is fixedly installed, and the armature can move flexibly within the frame cavity under the influence of the magnetic field. Under the influence of the magnetic field generated by the coil current, the stop and armature can be rapidly magnetized, forming a magnetic field unit. According to the structural sequence, the magnetic pole order is: N-stop S; N-armature S. Due to the magnetic field characteristics of opposite poles attracting each other, the armature is attracted to the stop, pushing the push rod to open the front valve. When the current direction is opposite and the magnetic pole order is reversed: S-stop N; S-armature N, although the magnetic pole directions are opposite, they are still attracted to each other, and the armature is attracted to the stop, pushing the push rod to open the front valve. Therefore, the direction of the electromagnetic thrust remains unchanged. Thus, the winding direction of the electromagnet (left-hand or right-hand) is unaffected. When the electromagnet coil is de-energized, the current magnetic field disappears, and the magnetic field of the soft magnetic material (with low coercivity and low remanence) also almost disappears. The electromagnetic force between the stop and the armature also disappears, and the armature returns to its initial position under the action of the front valve spring.

[0003] During long-term use and disassembly / repair of electromagnets, corrosion, insulation failure, damage to the enameled wire, and substandard electromagnet performance can render them unusable, leading to their scrapping. Therefore, designing a device and method for repairing electromagnets is of great significance in electromagnet maintenance.

[0004] However, by disassembling the existing original electromagnet, it can be found that in order to make room for the enameled wire and the lead wire connector to be embedded inside the coil, the number of turns in each layer of the coil is not the same, the layers are not distinct and irregular. From the appearance, the enameled wire at both ends is more disordered and has fewer turns, while the middle has more turns and is arranged more regularly. Furthermore, further disassembly reveals that the number of turns at both ends of each layer does not decrease in an arithmetic sequence, but rather they are interleaved, which is obviously a manual winding characteristic.

[0005] Therefore, it is quite challenging to ensure that the welding joint between the enameled wire and the lead wire can be successfully embedded inside the coil, while also ensuring that the coil wiring is neat and not loose, and to eliminate skipped wires and sparseness caused by the cumulative error of the enameled wire diameter during the winding process; how to control the tension of the enameled wire; and how to express the servo relationship between the wire feeding function and the spindle driving the skeleton to rotate and wind the wire. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention proposes an electromagnet winding process and apparatus. By utilizing the existing electromagnet frame, the coil is rewound to restore the original design and allow for continued use, thereby improving the maintenance quality and spare parts utilization rate of aircraft electromagnets. This is of great significance in electromagnet maintenance operations.

[0007] The technical problem to be solved by this invention is achieved by the following technical solution:

[0008] An electromagnet winding device includes a frame and a tensioner frame;

[0009] The top of the frame is provided with a large base plate, on which a tail top mechanism, a spindle box, a winding motor, and a wire laying mechanism are correspondingly arranged. The tail top mechanism is arranged opposite to the spindle box, the winding motor is connected to the spindle box, a wire feeding mechanism is slidably mounted on the wire laying mechanism, and a winding length detection mechanism is fixedly mounted on the wire feeding mechanism. The wire laying mechanism is located on the side between the tail top mechanism and the spindle box.

[0010] A servo motor-driven wire feeding tensioner is fixedly installed at the upper end of the tensioner frame, and enameled wire is placed at the bottom of the tensioner frame.

[0011] The enameled wire is actively fed out by the servo motor active wire tensioner. After the winding length detection mechanism calculates the length of the enameled wire, it is guided to wind in the X and Y directions by the wire feeding mechanism and the wire laying mechanism. It also works with the tail top mechanism and the main spindle box to clamp the electromagnet frame and drive the electromagnet frame to rotate to realize the electromagnet winding.

[0012] Preferably, the tail-top mechanism includes a slide rail fixedly mounted on the large base plate, a slider slidably mounted on the slide rail, a cylinder bracket and an air source bracket mounted on the slider, a cylinder mounted on the cylinder bracket, a center connected to the cylinder, an air source stabilizer mounted on the air source bracket, a locking mechanism on the slider, and the output air pressure of the air source stabilizer is 0.5 to 0.6 MPa.

[0013] Preferably, the spindle box is provided with a spindle connected to the winding motor inside, the spindle is connected to a rotating shaft in a detachable manner, and a touch screen is installed on the outside of the spindle box.

[0014] Preferably, the wound motor includes a wound motor mounting bracket fixedly mounted on the base plate, a spindle servo motor mounted on the wound motor mounting bracket, and a speed sensor connected to the spindle servo motor. The spindle servo motor is connected to the spindle in the spindle box via gears.

[0015] Preferably, the winding length detection mechanism includes a length detection mounting plate fixedly installed on the wire feeding mechanism, an encoder disposed on the length detection mounting plate, three wire feeding wheels, two wire guiding wheels, an encoder drive wheel, a wire pressing synchronous belt, and three synchronous belt pulleys. The encoder is connected to the encoder drive wheel, and the wire pressing synchronous belt is connected to the encoder drive wheel and the three synchronous belt pulleys.

[0016] Preferably, the wire feeding mechanism includes a wire feeding precision linear module mounted on the wire feeding mechanism, a wire feeding servo motor connected to the wire feeding precision linear module via a coupling, a wire feeding mounting plate connected to the wire feeding precision linear module, an adjustable wire feeding wheel connected to the wire feeding mounting plate, and a winding length detection mechanism connected to the wire feeding mounting plate.

[0017] Preferably, the wiring mechanism includes a mounting base fixedly mounted on the base plate, a wiring precision linear module fixedly mounted on the mounting base, and a wiring servo motor connected to the wiring precision linear module via a coupling. The wiring precision linear module is mounted on the wiring precision linear module via a connecting plate.

[0018] Preferably, the servo motor active wire feeding tensioner is model SF600, with a tension range of 20-450g.

[0019] An electromagnet winding process, employing an electromagnet winding device, includes the following specific steps:

[0020] Step (1) Select the corresponding rotating shaft according to the model of the electromagnet frame, insert the rotating shaft into the main shaft hole and tighten the connection with the locking screw. Clamp the electromagnet frame through the rotating shaft and the tail top mechanism.

[0021] Step (2) Place the enameled wire coil at the bottom of the tensioner frame. Pull out the wire end and pass it through the wire feeding wheel of the servo motor active wire feeding tensioner. Then, introduce it into the winding length detection mechanism. First, pass it through two wire feeding wheels and between the encoder drive wheel and the synchronous belt pulley. Then, pass it out through two wire feeding wheels and pass it through three wire feeding wheels in sequence. Then, the wire end passes through the adjustable wire feeding wheel and the wire feeding needle in the adjustable wire feeding wheel in sequence. Then, put the enameled wire into the lead wire groove on the electromagnet frame and pull it slightly tight. After wrapping the enameled wire end around the shaft locking screw once, use paper tape to stick the wire end to the shaft to prevent it from loosening. Rotate the shaft once to evenly attach the enameled wire close to the end.

[0022] Step (3) During the winding process, the winding length detection mechanism detects the winding length of the enameled wire, and the touch screen on the spindle box calculates the resistance of the coil and displays the value to determine whether the resistance of the electromagnet coil meets the technical specifications.

[0023] Step (4) During the winding process, after each layer is wound, the wire guide needle in the adjustable wire guide wheel automatically retracts one wire diameter distance along the Y direction. After each rotation of the main shaft, the wire guide needle in the adjustable wire guide wheel automatically moves one wire diameter distance along the X direction under the drive of the wire guide mechanism.

[0024] Step (5) Errors will occur when the wiring mechanism moves along the X direction. When the cumulative error exceeds three turns of diameter, it should be dealt with in a timely manner.

[0025] Step (VI) Repeat steps (IV) to (V) until the set number of windings is completed.

[0026] Preferably, the specific processing procedure for the cumulative error of the wire laying mechanism in step (v) is as follows: First, press the "Start / Stop" key on the touch screen on the spindle box to pause the winding. Then, press the "←" or "→" key on the touch screen on the spindle box to change the position of the wire laying mechanism. At the same time, use a segmented fitting method to express the relationship between the input and output of the spindle motor and the stepper motor nonlinearly. According to the enameled wire state on the layer, set each parameter layer by layer to synchronize the wire laying mechanism with the spindle movement and eliminate the cumulative error of the wire laying mechanism.

[0027] The beneficial effects of this invention are:

[0028] The winding device in this invention eliminates the cumulative movement error of the winding mechanism by using a segmented fitting method. It features simple operation, convenient use and maintenance, high servo control precision, strong practicality, safety, and reliability. The winding method in this invention can effectively restore the electromagnetic force of the electromagnet coil to its original design state, ensuring stable performance and enabling 100% reuse of scrapped electromagnets. This improves the maintenance quality of aircraft electromagnets and the utilization rate of spare parts, with broad application prospects and significant military, economic, and social benefits. Attached Figure Description

[0029] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0030] Figure 1 This is a schematic diagram of an existing electromagnet.

[0031] Figure 2 This is a schematic diagram of the overall structure of this embodiment;

[0032] Figure 3 This is a schematic diagram of the tail-top mechanism in this embodiment;

[0033] Figure 4 This is a schematic diagram showing the connection relationship between the wound motor and the spindle box in this embodiment;

[0034] Figure 5 This is a schematic diagram of the winding length detection mechanism in this embodiment. Figure 1;

[0035] Figure 6 This is a schematic diagram of the winding length detection mechanism in this embodiment. Figure 2 ;

[0036] Figure 7 This diagram illustrates the connection relationship between the winding length detection mechanism, the wire feeding mechanism, and the wire laying mechanism in this embodiment. Figure 1 ;

[0037] Figure 8 This diagram illustrates the connection relationship between the winding length detection mechanism, the wire feeding mechanism, and the wire laying mechanism in this embodiment. Figure 2 ;

[0038] Figure 9 This is a schematic diagram showing the connection relationship between the servo motor active wire feeding tensioner and the tensioner frame in this embodiment;

[0039] Figure 10 This is a schematic diagram of the wiring path of the enameled wire in the winding length detection mechanism in this embodiment;

[0040] Figure 11 This is a schematic diagram illustrating the height adjustment of the wire feeding needle in the adjustable wire feeding wheel of the wire feeding mechanism in this embodiment;

[0041] Figure 12 This is a schematic diagram of the electromagnet skeleton in this embodiment.

[0042] In the diagram: 1. Frame; 2. Tail top mechanism; 201. Slider; 202. Locking mechanism; 203. Slide rail; 204. Cylinder bracket; 205. Center; 206. Cylinder; 207. Air source stabilizer; 208. Air source bracket; 3. Base plate; 4. Spindle box; 5. Winding motor; 6. Winding length detection mechanism; 601. Encoder; 602. Length detection mounting plate; 603. Wire guide wheel; 604. Wire guide. 605. Encoder drive wheel; 606. Wire pressing synchronous belt; 607. Synchronous belt pulley; 7. Wire feeding mechanism; 701. Wire feeding precision linear module; 702. Wire feeding servo motor; 703. Wire feeding mounting plate; 704. Adjustable wire feeding wheel; 8. Wire feeding mechanism; 801. Mounting base; 802. Wire feeding precision linear module; 803. Wire feeding servo motor; 9. Servo motor active wire feeding tensioner; 10. Tensioner frame. Detailed Implementation

[0043] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0044] like Figure 2As shown, an electromagnet winding device includes a frame 1, a tail top mechanism 2, a base plate 3, a spindle box 4, a winding motor 5, a winding length detection mechanism 6, a wire feeding mechanism 7, a wire laying mechanism 8, a servo motor active wire feeding tensioner 9, a tensioner frame 10, and related accessories (power cord, fuse, socket, fixing screws, etc.).

[0045] The large base plate 3 is fixedly installed on the top of the frame 1. The tail top mechanism 2, spindle box 4, winding motor 5, and wire laying mechanism 8 are correspondingly fixedly installed on the large base plate 3. The tail top mechanism 2 is arranged opposite to the spindle box 4. The winding motor 5 is connected to the spindle box 4. The winding length detection mechanism 6 is installed on the wire feeding mechanism 7. The wire feeding mechanism 7 is slidably installed on the wire laying mechanism 8. The wire laying mechanism 8 is located at the rear side position between the tail top mechanism 2 and the spindle box 4. The tensioner frame 10 is located on the rear side of the frame 1. The servo motor active wire feeding tensioner 9 is installed on the top of the tensioner frame 10.

[0046] Furthermore, the rack 1, including the cabinet, is made of steel plate with powder coating, and has external dimensions of 1000mm (length) × 700mm (width) × 800mm (height) and a weight of 300KG. The cabinet interior is divided into two parts by electrical insulating plywood. One part (divided into three layers) can store tools, fixtures, necessary technical documents, and accessories, while the other part is treated with a three-proof coating (moisture, mold, and fungus protection) for installing circuit boards, cable trays, etc.

[0047] Furthermore, such as Figure 3 As shown, the tail top mechanism 2 consists of a slider 201, a locking mechanism 202, a slide rail 203, a cylinder bracket 204, a top point 205, a cylinder 206, an air source stabilizer 207, an air source bracket 208, and corresponding connecting fixing screws.

[0048] The slide rail 203 has dimensions of 450mm (length) × 100mm (width) × 20mm (height) and is made of stainless steel. A "⊥" shaped groove, 20mm from the edge, is arranged on the inner side of the slide rail 203. The groove is 20mm wide and 350mm long, and is used to install two "⊥" shaped bolts (composed of threaded studs at both ends and a square block with a threaded hole in the middle, both made of stainless steel) of the locking mechanism 202. The "⊥" shaped bolts pass through the two holes in the slider 201, and then the two handles of the locking mechanism 202 are placed on top (the handle holes are "⊥" shaped holes, which mate with the "⊥" shaped threaded studs on the upper end of the bolts) and secured with screws and washers. Turning the handles clockwise locks the slider 201, and turning them counterclockwise releases the slider 201, allowing it to slide freely on the slide rail 203.

[0049] The slider 201 has dimensions of 180mm (length) × 150mm (width) × 100mm (height), and is made of stainless steel (with a hollow center to reduce weight). The lower part is concave and precisely clearance-fits the slide rail 203. The upper part is used to mount the cylinder bracket 204 and the air source bracket 208. The cylinder 206 is mounted on the cylinder bracket 204, and the air source stabilizer 207 is mounted on the air source bracket 208, both secured with screws. Both the cylinder bracket 204 and the air source bracket 208 are made of stainless steel plate, and the cylinder 206 and the air source stabilizer 207 are pre-finished parts (selected from AIRTAC or equivalent brands).

[0050] The tip 205 is installed on the left side of the cylinder 206. On the one hand, it can support the electromagnet frame rigidly under a certain air pressure. On the other hand, under the effect of air suspension, the tip 205 does not contact the inner wall of the cylinder 206. This reduces wear when rotating with the main shaft of the electromagnet frame and ensures that the rotation is coaxial and does not wobble. The air source stabilizer 207 can stably output an air pressure of 0.5 to 0.6 MPa.

[0051] The base plate 3 is made of stainless steel and has dimensions of 920mm (length) × 650mm (width) × 25mm (height). It is fixedly mounted on the frame 1 with screws.

[0052] Furthermore, such as Figure 4 As shown, the spindle housing 4 is a welded stainless steel plate component. The dimensions of the spindle housing 4 are: 250mm (length) × 300mm (width) × 310mm (height). A touchscreen and control buttons are installed on the external panel of the spindle housing 4. The spindle and spindle bracket (with high-precision bearings in the bracket) are installed inside the spindle housing 4. The rotating shaft, stop pin, and top cover (made of magnetic material so it can be attached to the winding frame) are machined to match the corresponding dimensions of different electromagnet winding frames. The rotating shaft is inserted into the spindle hole and tightened with locking screws. See [link / details]. Figure 3 The spindle is driven by a wound motor, with a spindle speed of 0–500 rpm (depending on the wire diameter), and is controlled by a speed sensor. The wound wire diameter range is 0.1–1.0 mm.

[0053] Furthermore, the wound motor 5 consists of a mounting bracket, a spindle servo motor, and a speed sensor. The mounting bracket is CNC machined from stainless steel plate according to the mounting dimensions of the spindle servo motor and the speed sensor, and is fixedly mounted on the base plate 3 with screws. The spindle servo motor is selected from high-precision Mitsubishi (or equivalent brand) finished parts, and the speed sensor is selected from high-precision Omron (or equivalent brand) finished parts.

[0054] Furthermore, such as Figure 5 and Figure 6As shown, the winding length detection mechanism 6 consists of an encoder 601, a length detection mounting plate 602, three wire guide rollers 603, two wire feeding rollers 604, an encoder drive roller 605, a wire pressing synchronous belt 606, and three synchronous belt pulleys 607. The encoder 601 is connected to the encoder drive roller 605, and the wire pressing synchronous belt 606 is connected to the encoder drive roller 605 and the three synchronous belt pulleys 607.

[0055] Before winding, the wire is wound once around the encoder drive wheel 605. During winding, the wire-pressing synchronous belt 606 presses the enameled wire tightly, causing the enameled wire to drive the encoder drive wheel 605 to rotate. The encoder 601 counts, thus obtaining a precise value for the length of the enameled wire. From the enameled wire length value, the PLC software in the touch screen on the spindle box 4 can calculate the precise coil resistance value according to the formula R = ρ × (L1 + L2) / S + R1, and the touch screen displays the value. (Copper wire resistivity ρ = 0.0172, L1 is the measured enameled wire length, L2 is the starting wire length, S is the cross-sectional area of ​​the enameled wire, and R1 is the compensation resistance value). To reduce friction, the wire guide wheel 603, the wire feed wheel 604, the encoder drive wheel 605, and the synchronous belt pulley 607 are all mounted on the length detection mounting plate 602 using high-precision ball bearings. The length detection mounting plate 602 is fixed to the wire feeding mechanism 7 with screws.

[0056] Furthermore, such as Figure 7 , Figure 8 As shown, the wire feeding mechanism 7 consists of a wire feeding precision linear module 701, a wire feeding servo motor 702, a wire feeding mounting plate 703, and an adjustable wire feeding wheel 704.

[0057] The wiring mechanism 8 consists of a mounting base 801, a wiring precision linear module 802, and a wiring servo motor 803.

[0058] The aforementioned precision linear wire feeding module 701 and precision linear wire laying module 802 are both made of precision worm gear and zigzag beam; the adjustable wire laying wheel 704 includes a support rod, a wire laying needle and an intermediate shaft.

[0059] In the wire feeding mechanism 7, the adjustable wire feeding wheel 704 is fixedly mounted on the wire feeding mounting plate 703 by a mounting bracket and screws. The wire feeding mounting plate 703 is fixedly mounted on the wire feeding precision linear module 701 by screws (in essence, the wire feeding mounting plate 703 is fixed on the worm gear in the wire feeding precision linear module 701). The wire feeding servo motor 702 is connected to the wire feeding precision linear module 701 by a coupling (in essence, the output shaft of the wire feeding servo motor 702 is connected to the worm gear in the wire feeding precision linear module 701 by a coupling) and is fixed with screws and flanges.

[0060] In the wiring mechanism 8, the wiring servo motor 803 is connected to the wiring precision linear module 802 via a coupling (essentially, the output shaft of the wiring servo motor 803 is connected to the worm gear in the wiring precision linear module 802 via a coupling), and is fixed with screws and flanges. At the upper part of the wiring mechanism 8, the wire feeding precision linear module 701 in the wire feeding mechanism 7 is connected to the wiring precision linear module 802 via a connecting plate (essentially, the wire feeding precision linear module 701 is fixed to the worm gear in the wiring precision linear module 802 via the connecting plate), and is fixed with screws. The lower part of the wiring mechanism 8 is fixedly mounted on the base plate 3 with screws via an I-beam mounting bracket 801.

[0061] The wire feeding mechanism 7 is set according to the number of layers of the coil wound by the electromagnet. The wire feeding servo motor 702 drives the wire feeding precision linear module 701 to drive the adjustable wire feeding wheel 704 to move longitudinally (Y direction) and control the wire feeding distance of the wire feeding needle. It can automatically retreat by one wire diameter distance after each layer is wound. In this way, collisions can be avoided when the product is wound larger and larger. The maximum rotatable diameter of the wire feeding mechanism 7 is 200mm.

[0062] The wire laying mechanism 8, based on the slot width of the wound electromagnet coil, is driven by the wire laying servo motor 803, which in turn drives the wire feeding mechanism 7 and its adjustable wire laying wheel 704 to move laterally (in the X direction). Following the output command from the spindle speed sensor inside the spindle box 4, for every revolution of the spindle inside the spindle box 4, the wire laying servo motor 803 drives the wire laying precision linear module 802 to drive the adjustable wire laying wheel 704 to move laterally (in the X direction) by one wire diameter distance. The stroke range of the wire laying mechanism 8 is 0–200 mm.

[0063] The intermediate shaft of the adjustable cable guide wheel 704 is inserted into the bracket and slightly tightened with screws, allowing manual adjustment of the appropriate height (Z direction) of the cable guide nozzle. The cable guide nozzle is made of wear-resistant tungsten steel, and the inner surface of the bore is precision ground by abrasive flow (Ra0.4) to avoid wear or scratch damage to the enameled wire.

[0064] like Figure 9 As shown, the servo motor-driven active wire tensioner 9 is model SF600. It actively feeds the wire following the spindle speed of the winding device, ensuring stable tension and preventing the enameled wire from being incorrectly stretched thin due to tension. It also features high following accuracy and fast response. Tension range: 20-450g.

[0065] The tensioner frame 10 is made of angle steel and steel plate with powder coating, and is 980mm high. The upper part of the tensioner frame 10 is used to install the servo motor active wire feeding tensioner 9, and the lower part (600mm (length) × 500mm (width) × 50mm (height) is used to hold the enameled wire.

[0066] A method of using an electromagnet winding device, wherein the above-described electromagnet winding device is used to, as follows: Figure 12 Taking the electromagnet frame shown as an example, we will perform electromagnet winding.

[0067] The power supply voltage for the electromagnet winding device is 220V±10%, and the middle pin of the three-core plug for the single-phase power supply must be reliably grounded. The air source pressure is 1MPa±10%.

[0068] The control system of the electromagnet winding device uses a PLC as the main controller and a touch screen on the spindle box 4 as the human-machine interface. The winding system is operated using the touch screen, and the functions include individual actions and linkage actions of each system, inching operation, continuous operation, forward and reverse rotation settings for take-up and give-up, left and right movement settings for the wire laying, speed and wire diameter settings, single-layer operation, and multi-layer continuous operation. The motion parts include the take-up spindle movement, the wire feeding spindle movement, the wire laying frame lifting mechanism, and the left and right movement mechanism for the wire laying.

[0069] The specific steps are as follows:

[0070] Step (1) Select the corresponding rotating shaft according to the model of the electromagnet frame, insert the rotating shaft into the main shaft hole and tighten the connection with the locking screw, and clamp the electromagnet frame through the rotating shaft and the tail top mechanism 2.

[0071] Specifically, after the shaft is inserted into the spindle hole, it is tightened with a locking screw. To ensure the coaxiality of the shaft rotation, the runout of the shaft should be measured. The runout should not exceed 0.05mm to ensure that the bobbin is not eccentric during winding. The center point of the tail-end mechanism 2 should also be coaxial with the central axis of the shaft. When moving the tail-end mechanism 2 by releasing the handle, the center point should lightly touch the top cover. Then, turn the handle clockwise to lock it. Subsequently, the voltage regulator outputs 0.5-0.6MPa, the spindle speed is 0-500rpm (depending on the wire diameter), and the winding wire diameter range is 0.1-1.0mm.

[0072] Step (II) The enameled wire coil is placed at the bottom of the tensioner frame 10. After pulling out the wire end, it passes through the wire feeding wheel of the servo motor active wire feeding tensioner 9 and is introduced into the winding length detection mechanism 6. First, it passes through two wire feeding wheels 604 and between the encoder transmission wheel 605 and the synchronous belt pulley 607. Then, it exits from the two wire feeding wheels 604 and passes through three wire guiding wheels 603 in sequence. Subsequently, the wire end passes through the adjustable wire guiding wheel 704 on the wire feeding mechanism 7 and the wire guiding needle in the adjustable wire guiding wheel. Then, the enameled wire is placed into the lead wire groove on the electromagnet frame and slightly tightened. After wrapping the enameled wire end once around the shaft locking screw, the wire end is glued to the shaft with paper tape to prevent loosening. Rotate the shaft once to evenly attach the enameled wire close to the end. Figure 10As shown. The direction of the rotating shaft can be clockwise or counterclockwise, but it must be consistent with the rotation direction set in the subsequent program.

[0073] In step (iii), during the winding process, the winding length detection mechanism 6 detects the winding length of the enameled wire. The PLC software on the touch screen of the spindle box 4 calculates the resistance of the coil and displays the value to determine whether the resistance of the electromagnet coil meets the technical specifications. The servo motor actively feeds the wire tensioner 9, following the spindle speed on the spindle box 4. The tension is stable, and the enameled wire will not be incorrectly stretched thin due to tension.

[0074] In step (four), during the winding process, the wire feeding servo motor 702 drives the wire feeding precision linear module 701 to drive the adjustable wire feeding wheel 704 to move longitudinally (in the Y direction), controlling the wire feeding distance of the wire feeding needle on the adjustable wire feeding wheel 704, so that it can automatically retreat by one wire diameter after each layer is wound. The maximum rotatable diameter of the wire feeding mechanism 7 is 200mm.

[0075] The left and right movement of the cable guide mechanism 8 is achieved by following the output commands from the spindle speed sensor inside the spindle box 4. The cable guide system consists of a position loop, a speed loop, and a current loop. The position loop compares the given position with the actual feedback position from the motor to minimize the error. The speed loop adjusts the motor current, i.e., the motor speed, in real time based on the feedback. The speed of the speed loop determines the dynamic response speed of the entire system. The current loop is mainly used to calculate the torque of the motor drive and can automatically optimize the setting parameters based on pre-saved motor data. This ensures that for every revolution of the spindle, the cable guide servo motor 803 drives the cable guide precision linear module 802 to move the adjustable cable guide wheel 704 laterally (in the X direction) by one wire diameter distance.

[0076] Furthermore, such as Figure 11 As shown, the height of the thread-laying needle in the adjustable thread-laying wheel 704 can be manually adjusted. This ensures that the scientifically reasonable bend angle at the needle tube is between 5° and 20° when the enameled wire begins to wind and when the bobbin is fully wound. If the bend angle is too small, the thread will not be neatly laid; if the bend angle is too large, the enameled wire will be subjected to too much force at the needle tube, which will easily cause the wire to rub, the needle tube to overheat, and the needle tube to wear out easily.

[0077] Step (5) When the wiring mechanism 8 moves along the X direction, errors will occur. When the cumulative error exceeds the distance of three turns of diameter, it should be dealt with in time.

[0078] Specifically, the movement of the winding mechanism 8 is related to the outer diameter of the enameled wire (including the thickness of the enamel coating, measured with a micrometer). For every revolution of the main shaft, the winding mechanism 8 moves by a displacement equal to the outer diameter of the enameled wire, and the electromagnet winding device records one turn. Due to the uniformity of the enameled wire's outer diameter and the influence of the servo system's control precision, the movement of the winding mechanism 8 will produce errors. When these errors accumulate to a certain level, skipped wires or sparse coiling will occur during the winding process, leading to coil winding failure. Therefore, when the accumulated error of the winding mechanism 8 exceeds the diameter of three turns, it should be addressed promptly.

[0079] Furthermore, the specific process for handling the cumulative error of the wire laying mechanism 8 is as follows: First, press the "Start / Stop" key on the touch screen on the spindle box 4 to pause the winding. Then, press the "←" or "→" key on the touch screen on the spindle box 4 to change the position of the wire laying mechanism 8. At the same time, a piecewise fitting method is used to nonlinearly express the relationship between the input and output of the spindle motor and the stepper motor for one revolution. According to the enameled wire state on the number of layers, each parameter is set in layers. That is, the number of pulses per unit wire diameter is distributed to several states for control to achieve complete synchronization between the wire laying device and the spindle motor under the unit number of turns, thereby eliminating the cumulative error of the wire laying mechanism 8.

[0080] Step (VI) Repeat steps (IV) to (V) until the set number of windings is completed.

[0081] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely prisms of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. An electromagnet winding device, characterized in that: Includes frame (1) and tensioner frame (10); The top of the frame (1) is provided with a large base plate (3), and the large base plate (3) is provided with a tail top mechanism (2), a spindle box (4), a winding motor (5), and a wire laying mechanism (8). The tail top mechanism (2) is arranged opposite to the spindle box (4), the winding motor (5) is connected to the spindle box (4), the wire laying mechanism (8) is slidably mounted with a wire feeding mechanism (7), the wire feeding mechanism (7) is fixedly mounted with a winding length detection mechanism (6), and the wire laying mechanism (8) is located on the side between the tail top mechanism (2) and the spindle box (4). A servo motor active wire feeding tensioner (9) is fixedly installed at the upper end of the tensioner frame (10), and an enameled wire is placed at the bottom of the tensioner frame (10). The enameled wire is actively fed out from the servo motor active wire tensioner (9), and after the winding length detection mechanism (6) calculates the length of the enameled wire, it is guided to wind in the X and Y directions by the wire feeding mechanism (7) and the wire laying mechanism (8), and cooperates with the tail top mechanism (2) and the main spindle box (4) to clamp the electromagnet frame and drive the electromagnet frame to rotate to realize the electromagnet winding; The wire feeding mechanism (7) includes a wire feeding precision linear module (701) mounted on the wire feeding mechanism (8), a wire feeding servo motor (702) connected to the wire feeding precision linear module (701) via a coupling, a wire feeding mounting plate (703) connected to the wire feeding precision linear module (701), an adjustable wire feeding wheel (704) connected to the wire feeding mounting plate (703), and the winding length detection mechanism (6) connected to the wire feeding mounting plate (703). The wiring mechanism (8) includes a mounting base (801) fixedly mounted on the base plate (3), a wiring precision linear module (802) fixedly mounted on the mounting base (801), and a wiring servo motor (803) connected to the wiring precision linear module (802) via a coupling. The wiring precision linear module (701) is mounted on the wiring precision linear module (802) via a connecting plate.

2. The electromagnet winding device according to claim 1, characterized in that: The tail-top mechanism (2) includes a slide rail (203) fixedly installed on the large base plate (3), a slider (201) slidably installed on the slide rail (203), a cylinder bracket (204) and an air source bracket (208) set on the slider (201). A cylinder (206) is installed on the cylinder bracket (204), and a center point (205) is connected to the cylinder (206). An air source stabilizer (207) is installed on the air source bracket (208). A locking mechanism (202) is set on the slider (201). The output air pressure of the air source stabilizer (207) is 0.5 to 0.6 MPa.

3. The electromagnet winding device according to claim 1, characterized in that: The spindle box (4) is equipped with a spindle connected to the winding motor (5) inside. The spindle is connected to a rotating shaft in a detachable manner. A touch screen is installed on the outside of the spindle box (4).

4. The electromagnet winding device according to claim 3, characterized in that: The wound motor (5) includes a wound motor mounting bracket fixedly mounted on the base plate (3), a spindle servo motor mounted on the wound motor mounting bracket, and a speed sensor connected to the spindle servo motor. The spindle servo motor is connected to the spindle in the spindle box (4) through gears.

5. An electromagnet winding device according to claim 1, characterized in that: The winding length detection mechanism (6) includes a length detection mounting plate (602) fixedly installed on the wire feeding mechanism (7), an encoder (601) set on the length detection mounting plate (602), three wire feeding wheels (603), two wire guiding wheels (604), an encoder drive wheel (605), a wire pressing synchronous belt (606), and three synchronous belt pulleys (607). The encoder (601) is connected to the encoder drive wheel (605), and the wire pressing synchronous belt (606) is connected to the encoder drive wheel (605) and the three synchronous belt pulleys (607).

6. The electromagnet winding device according to claim 1, characterized in that: The servo motor active wire tensioner (9) is model SF600, with a tension range of 20-450g.

7. A method for winding an electromagnet, characterized in that: The specific steps of applying the electromagnet winding device according to claim 5 are as follows: Step (1) Select the corresponding matching shaft according to the model of the electromagnet skeleton, insert the shaft into the main shaft hole and tighten the connection with the locking screw, and clamp the electromagnet skeleton through the shaft and the tail top mechanism (2). Step (2) The enameled wire coil is placed at the bottom of the tensioner frame (10). After the wire end is pulled out and passes through the wire feeding wheel of the servo motor active wire feeding tensioner (9), it is introduced into the winding length detection mechanism (6). First, it passes through the two wire feeding wheels (604) and between the encoder transmission wheel (605) and the synchronous belt pulley (607). Then, it passes out through the two wire feeding wheels (604) and passes through the three wire feeding wheels (603) in sequence. Then, the wire end passes through the adjustable wire feeding wheel (704) on the wire feeding mechanism (7) and the wire feeding needle in the adjustable wire feeding wheel (704) in sequence. Then, the enameled wire is put into the lead wire groove on the electromagnet frame and slightly tightened. After the enameled wire end is wrapped around the shaft locking screw once, the wire end is glued to the shaft with paper tape to prevent loosening. Rotate the shaft once to evenly attach the enameled wire to the end. In step (3) during the winding process, the winding length detection mechanism (6) detects the winding length of the enameled wire, and the touch screen on the spindle box (4) calculates the resistance of the coil and displays the value to determine whether the resistance of the electromagnet coil meets the technical requirements. In step (four), during the winding process, after each layer is wound, the wire guide needle in the adjustable wire guide wheel (704) automatically retracts by one wire diameter distance in the Y direction. After each rotation of the main shaft, the wire guide needle in the adjustable wire guide wheel (704) automatically moves by one wire diameter distance in the X direction under the drive of the wire guide mechanism (8). Step (5) The wiring mechanism (8) will generate errors when it moves along the X direction. When the cumulative error of the movement exceeds the distance of three turns of diameter, it should be dealt with in time. The specific processing procedure for the cumulative error of the wire laying mechanism (8) in step (5) is as follows: First, press the "Start / Stop" key on the touch screen on the spindle box (4) to pause the winding. Then, press the "←" key or "→" key on the touch screen on the spindle box (4) to change the position of the wire laying mechanism (8). At the same time, the segmented fitting method is used to express the relationship between the input and output of the spindle motor and the stepper motor nonlinearly. According to the enameled wire state on the layer, each parameter is set layer by layer to synchronize the wire laying mechanism (8) with the spindle movement and eliminate the cumulative error of the wire laying mechanism (8). Step (VI) Repeat steps (IV) to (V) until the set number of windings is completed.

Images