A method for winding an inductor

Abstract

The present invention discloses an inductor winding method, belonging to the technical field of inductor manufacturing equipment. The winding method is based on a winding device, wherein the winding device comprises at least one group of working units, wherein the working units comprise a wire feeding mechanism, a positioning mechanism and a winding mechanism, wherein the positioning mechanism comprises a magnetic ring clamp and a flipping drive for driving the magnetic ring clamp to flip 180 degrees. By adopting a segmented winding method, the segmented wire feeding of the wire feeding mechanism, the repeated winding of the winding mechanism and the head-to-tail switching of the flipping drive are utilized to realize winding of the winding wire from both ends in the same manner, thereby greatly shortening the winding length of the wire hook during winding, improving the inductor winding efficiency, and the inductor performance parameters produced by the equipment can fully meet the standards of manual winding.

Description

Technical Field

[0001] The invention relates to the technical field of inductor manufacturing equipment, in particular to an inductor winding method. Background Art

[0002] The existing inductor winding machines with the same winding direction generally start from one end of the winding, such as the winding head, and wind the winding wire around the magnetic ring winding part one circle at a time. Due to different needs, the length of the winding wire is also different. The above winding method has problems such as long equipment hooking time, low processing efficiency, and the inductor performance compliance rate needs to be improved. Summary of the invention

[0003] In order to overcome the deficiencies of the prior art, the present invention provides an inductor winding method, which has a reasonable and ingenious structure and greatly improves the processing efficiency and the inductor performance compliance rate.

[0004] The technical solution adopted by the present invention to solve its technical problem is:

[0005] An inductor winding method, the winding method is based on a winding device, the winding device includes at least one group of working units, the working unit includes a wire feeding mechanism, a positioning mechanism and a winding mechanism, the positioning mechanism includes a magnetic ring clamp, and a flip drive that drives the magnetic ring clamp to flip 180 degrees;

[0006] The inductor winding method comprises:

[0007] Step S1: According to a preset winding length, controlling the wire feeding mechanism to feed a certain length of winding wire to the magnetic ring, the winding length being less than the preset winding length;

[0008] Step S2: Controlling the winding mechanism to wind the winding wire end around the winding portion of the magnetic ring to form a first winding, and after the winding mechanism completes winding of one circle of the winding portion, the winding mechanism moves a preset distance along the circumferential direction of the winding portion, so that each circle of winding can be arranged in sequence on the winding portion;

[0009] Step S3: Control the winding mechanism to reset along the circumferential direction of the winding portion, and the flipping drive drives the magnetic ring clamp to flip 180°;

[0010] Step S4: Control the winding mechanism to wind the winding wire tail around the winding part of the magnetic ring to form a second winding. After the winding mechanism completes winding of one circle of the winding part, the winding mechanism moves a preset distance along the circumferential direction of the winding part so that each circle of winding can be arranged in sequence on the winding part.

[0011] Preferably, in step S1, the wire feeding mechanism is controlled to feed half the length of the winding wire or three quarters of the length of the winding wire to the magnetic ring.

[0012] Preferably, when the wire feeding mechanism feeds half the length of the winding wire to the magnetic ring, the first winding is wound identically to the second winding.

[0013] Preferably, the first winding and the second winding are single-layer windings or double-layer windings.

[0014] Preferably, the winding mechanism comprises a winding device, a hook device and a rotation drive for driving the winding device and the hook device to rotate along the circumferential direction of the winding portion;

[0015] Then the control winding mechanism winds the winding wire head and the winding wire tail on the winding part of the magnetic ring, specifically including:

[0016] For each winding circle, the winding device is controlled to flip the winding below the magnetic ring to the top of the magnetic ring and place it horizontally, and the hook device is controlled to extend from the center of the magnetic ring to hook the winding from the top of the magnetic ring to the bottom of the magnetic ring to complete a winding circle.

[0017] Preferably, the winding mechanism further comprises an infrared counter arranged at the winding device, and the infrared counter is used to sense and record the number of winding turns completed by the winding device.

[0018] Preferably, the winding device comprises a winding drive and a winding rod eccentrically connected to the output end of the winding drive, the winding rod having a winding wheel capable of clamping the winding wire;

[0019] Then the control winding device flips the winding below the magnetic ring to above the magnetic ring and places it horizontally, specifically including:

[0020] The control winding drive drives the winding rod to make eccentric movement at the magnetic ring, driving the winding wheel to hook the wire from below the magnetic ring, then retract and rise again and flip the wire to above the magnetic ring.

[0021] Preferably, the rotary drive comprises a mounting frame, a rotary motor, a transmission cylinder rotatably disposed on the mounting frame, and a gear set for transmission connecting the rotary motor and the transmission shaft, and the winding device and the hook device are fixed on the transmission cylinder.

[0022] Preferably, the winding equipment comprises two groups of working units, and a transfer device and a material transfer device arranged between the two groups of working units, and the material transfer device can drive the magnetic ring to move between the working unit and the transfer device;

[0023] The inductor winding method further comprises:

[0024] Control the material transfer device to send the magnetic ring wound by one of the working units to the transfer device;

[0025] Control the transfer device to rotate 180°;

[0026] The material transfer device is controlled to send the magnetic ring at the transfer device to another working unit.

[0027] Preferably, the winding equipment also includes an automatic magnetic ring feeding device.

[0028] The beneficial effects of the present invention are as follows: the present invention adopts a segmented winding method, which is based on a winding device, wherein the winding device includes at least one group of working units, wherein the working unit includes a wire feeding mechanism, a positioning mechanism and a winding mechanism, wherein the positioning mechanism includes a magnetic ring clamp and a flipping drive that drives the magnetic ring clamp to flip 180°. By utilizing the segmented wire feeding of the wire feeding mechanism, the repeated winding of the winding mechanism and the head-to-tail switching of the flipping drive, the winding is realized in the same manner from both ends of the winding wire, which greatly shortens the winding length of the wire hook during winding, improves the efficiency of inductor winding, and the performance parameters of the inductor produced by the equipment can fully meet the standards of manual winding. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a structural schematic diagram of the winding device of the present invention;

[0030] Figure 2 It is a structural schematic diagram of the working unit of the present invention;

[0031] Figure 3 It is a structural schematic diagram of the positioning mechanism of the present invention;

[0032] Figure 4 It is a structural schematic diagram of the winding mechanism of the present invention;

[0033] Figure 5 It is a structural schematic diagram of the wire feeding mechanism of the present invention;

[0034] Figure 6 It is a flow chart of the inductor winding method of the present invention. DETAILED DESCRIPTION

[0035] The technical solution of the present invention is described in detail below in conjunction with the accompanying drawings and embodiments.

[0036] like Figure 1-6 As shown, the winding device of the embodiment of the present invention includes at least one group of working units 1, the working unit 1 includes a wire feeding mechanism 2, a positioning mechanism 3 and a winding mechanism 4, the positioning mechanism 3 includes a magnetic ring clamp 5 and a flipping drive 6 for driving the magnetic ring clamp 5 to flip 180 degrees. The magnetic ring clamp 5 is used to fix the magnetic ring, and the flipping device is used to flip the magnetic ring after the winding mechanism 4 uses the winding wire head to wind the first winding, so that the winding mechanism 4 uses the winding wire tail and the same winding method to wind the second winding.

[0037] Specifically, the inductor winding method includes:

[0038] Step S1: According to a preset winding length, the wire feeding mechanism 2 is controlled to feed a certain length of winding wire to the magnetic ring, and the winding length is less than the preset winding length;

[0039] Step S2: Control the winding mechanism 4 to wind the winding wire end on the winding portion of the magnetic ring to form a first winding. After the winding mechanism 4 completes winding of one circle of the winding portion, the winding mechanism 4 moves a preset distance along the circumferential direction of the winding portion, so that each circle of winding can be arranged in sequence on the winding portion;

[0040] Step S3: Control the winding mechanism 4 to reset along the circumferential direction of the winding portion, and the flip drive 6 drives the magnetic ring clamp 5 to flip 180°;

[0041] Step S4: Control the winding mechanism 4 to wind the winding wire tail around the winding part of the magnetic ring to form a second winding. After the winding mechanism 4 completes winding of one circle of the winding part, the winding mechanism 4 moves a preset distance along the circumferential direction of the winding part so that each circle of winding can be arranged in sequence on the winding part.

[0042] The present invention adopts a segmented winding method, utilizing the segmented wire feeding of the wire feeding mechanism 2, the repeated winding of the winding mechanism 4, and the head-to-tail switching of the flip drive 6 to realize winding the windings in the same manner from both ends of the winding wire, thereby greatly shortening the winding length of the wire during winding, improving the inductor winding efficiency, and the inductor performance parameters produced by the equipment can fully meet the standards of manual winding.

[0043] Preferably, in the winding method implemented by the winding device, in step S1, the wire feeding mechanism 2 is controlled to feed half the length of the winding wire or three quarters of the length of the winding wire to the magnetic ring. The first winding and the second winding can be single-layer windings or double-layer windings.

[0044] The above technical solution is described in detail below with reference to the accompanying drawings and embodiments:

[0045] Embodiment 1: The wire feeding mechanism 2 feeds half the length of the winding wire to the magnetic ring for winding a common common mode inductor

[0046] The inductor winding method is as follows:

[0047] Step S1: According to the preset winding length, the wire feeding mechanism 2 feeds half the length of the winding to the magnetic ring;

[0048] Step S2: Control the winding mechanism 4 to wind the winding wire end on the winding part of the magnetic ring to form a single-layer first winding; specifically, after the winding mechanism 4 completes winding of one circle of the winding part, the winding mechanism 4 moves a preset distance in the counterclockwise direction along the circumference of the winding part, so that half of the length of the winding wire can be arranged one circle at a time on the winding part in sequence;

[0049] Step S3: Control the winding mechanism 4 to reset in the clockwise direction along the circumference of the winding portion, and the flip drive 6 drives the magnetic ring clamp 5 to flip 180°;

[0050] Step S4: Control the winding mechanism 4 to wind the end of the winding wire around the winding part of the magnetic ring to form a single-layer second winding; specifically, after the winding mechanism 4 completes winding of one circle of the winding part, the winding mechanism 4 moves a preset distance in the counterclockwise direction along the circumference of the winding part, so that half the length of the winding can be arranged in circles on the winding part in sequence.

[0051] At this time, the first winding is wound in the same manner as the second winding.

[0052] Embodiment 2: The wire feeding mechanism 2 feeds half the length of the winding wire to the magnetic ring for winding a butterfly-type winding inductor

[0053] The inductor winding method is as follows:

[0054] Step S1: According to the preset winding length, the wire feeding mechanism 2 feeds half the length of the winding to the magnetic ring;

[0055] Step S2: Control the winding mechanism 4 to wind the winding wire end around the winding portion of the magnetic ring to form a double-layer first winding; specifically, after the winding mechanism 4 completes winding of one circle of the winding portion, the winding mechanism 4 moves a preset distance in the counterclockwise direction along the circumference of the winding portion, so that a quarter of the length of the winding wire can be arranged in turn in the first layer of the winding portion, and then the winding mechanism 4 moves in the clockwise direction along the circumference of the winding portion, so that the remaining quarter of the length of the winding wire can be arranged in turn in the second layer of the winding portion;

[0056] Step S3: At this time, the winding mechanism 4 is reset, and the flip drive 6 is controlled to drive the magnetic ring clamp 5 to flip 180°;

[0057] Step S4: Control the winding mechanism 4 to wind the tail of the winding wire around the winding part of the magnetic ring to form a double-layer second winding; specifically, after the winding mechanism 4 completes the winding of one circle of the winding part, the winding mechanism 4 moves a preset distance in the counterclockwise direction along the circumference of the winding part, so that one quarter of the length of the winding wire can be arranged in turn in the first layer of the winding part, and then the winding mechanism 4 moves in the clockwise direction along the circumference of the winding part, so that the remaining one quarter of the length of the winding wire can be arranged in turn in the second layer of the winding part.

[0058] At this time, the first winding is wound in the same manner as the second winding.

[0059] Embodiment 3: The wire feeding mechanism 2 feeds three-quarters of the length of the winding wire to the magnetic ring for winding a butterfly-type winding inductor

[0060] The inductor winding method is as follows:

[0061] Step S1: According to the preset winding length, the wire feeding mechanism 2 feeds three quarters of the length of the winding to the magnetic ring;

[0062] Step S2: Control the winding mechanism 4 to wind the winding wire end around the winding portion of the magnetic ring to form a first winding, wherein the first winding includes a first layer winding of half the length and a second layer winding of a quarter the length; specifically, after the winding mechanism 4 completes winding of one circle of the winding portion, the winding mechanism 4 moves a preset distance in the counterclockwise direction along the circumference of the winding portion, so that the winding of half the length can be arranged in turn in the first layer of the winding portion, and then the winding mechanism 4 moves in the clockwise direction along the circumference of the winding portion, so that the winding of the remaining quarter of the length can be arranged in turn in the second layer of the winding portion;

[0063] Step S3: Control the winding mechanism 4 to reset in the clockwise direction along the circumference of the winding portion, and the flip drive 6 drives the magnetic ring clamp 5 to flip 180°;

[0064] Step S4: Control the winding mechanism 4 to wind the tail of the winding wire on the winding part of the magnetic ring to form a second winding, and the second winding is wound on the first layer of winding formed in step S2; specifically, after the winding mechanism 4 completes the winding of one circle of the winding part, the winding mechanism 4 moves a preset distance in the counterclockwise direction along the circumference of the winding part, so that the winding of one quarter of the length can be arranged in turn in the winding part.

[0065] At this time, the first winding and the second winding are wound in different ways. The first winding is to firstly wind half of the winding length in the first layer in the counterclockwise direction along the circumference of the winding portion, and then reversely wind the remaining quarter of the winding length in the second layer in the clockwise direction along the circumference of the winding portion, while the second winding is to directly wind a quarter of the winding length in the second layer in the counterclockwise direction along the circumference of the winding portion.

[0066] In the third embodiment, since the first winding firstly winds the first layer of the butterfly-type winding inductor neatly and compactly, and then winds the quarter windings at both ends of the second layer respectively, the second layer will not cause the first layer of winding to slip or be squeezed, and the product quality is better and the performance is more stable.

[0067] like Figure 4 As shown, the winding mechanism 4 includes a winding device 7, a hook device 8 and a rotation drive 9 that drives the winding device 7 and the hook device 8 to rotate along the circumferential direction of the winding portion.

[0068] The controlling winding mechanism 4 will wind the winding head and the winding tail around the winding part of the magnetic ring, specifically including: for each circle of winding, controlling the winding device 7 to flip the winding below the magnetic ring to the top of the magnetic ring and place it horizontally, controlling the hook device 8 to extend from the center of the magnetic ring, hooking the winding from the top of the magnetic ring to the bottom of the magnetic ring, and completing one circle of winding.

[0069] Subsequently, the rotary drive 9 drives the winding device 7 and the hook device 8 to rotate a preset distance along the circumferential direction of the winding part, and the winding device 7 and the hook device perform the winding work of the next circle of winding. After the winding is completed, the rotary drive 9 drives the winding device 7 and the hook device 8 to rotate and reset along the circumferential direction of the winding part.

[0070] Preferably, the winding mechanism 4 further comprises an infrared counter arranged at the winding device 7 , and the infrared counter is used to sense and record the number of winding turns completed by the winding device 7 .

[0071] Specifically, the winding device 7 includes a winding drive 10 and a winding rod 11 eccentrically connected to the output end of the winding drive 10, and the winding rod 11 has a winding wheel 12 that can clamp the winding wire.

[0072] The controlling winding device 7 flips the winding below the magnetic ring to above the magnetic ring and places it horizontally, specifically including: controlling the winding drive 10 to drive the winding rod 11 to make eccentric movement at the magnetic ring, driving the winding wheel 12 to hook the wire from below the magnetic ring, then retract and rise again to flip the winding to above the magnetic ring.

[0073] The winding rod 11 is eccentrically connected to the output end of the winding drive 10 and is driven by it to make a circular motion around the output end of the winding drive 10. The winding rod 11 hooks the wire from below the magnetic ring, retracts, and then rises to above the magnetic ring to achieve two-dimensional motion, and flips the winding to facilitate the hook device 8 to hook the wire.

[0074] The hook device 8 comprises a hook and a lifting drive for driving the hook to lift. Further, the winding rod 11 has a recessed position for giving way to the hook, so as to facilitate fast hooking and winding.

[0075] The rotary drive 9 drives the winding device 7 and the hook device 8 to rotate synchronously along the circumferential direction of the winding part. Specifically, it includes a mounting frame 13, a rotary motor 14, a transmission cylinder 15 rotatably arranged on the mounting frame 13, and a gear set 16 that transmits and connects the rotary motor 14 and the transmission shaft. The winding device 7 and the hook device 8 are fixed on the transmission cylinder 15.

[0076] like Figure 5 As shown, the wire feeding mechanism 2 includes a wire feeding drive, a conductor structure 17, a wire release detection structure and a wire break structure 18 arranged on a base, and a wire feeding nozzle 19 is provided at the wire outlet end of the wire feeding drive.

[0077] like Figure 1 As shown, in order to realize the fully automatic winding of the magnetic ring, the winding equipment includes a magnetic ring automatic feeding device 20, two groups of working units 1, and a transfer device 21 and a material moving device 22 arranged between the two groups of working units 1, and the material moving device 22 can drive the magnetic ring to move between the working unit 1 and the transfer device 21;

[0078] The inductor winding method further comprises:

[0079] Control the material transfer device 22 to send the magnetic ring wound by one of the working units 1 to the transfer device 21;

[0080] Control the transfer device 21 to rotate 180°;

[0081] The material transfer device 22 is controlled to send the magnetic ring at the transfer device 21 to another working unit 1 .

[0082] During operation, the automatic magnetic ring feeding device 20 is used for vibration feeding of magnetic rings, and feeds the magnetic ring at the output end to one of the working units 1. After the working unit 1 completes the winding using a segmented winding method, the material transfer device 22 sends it to the transfer device 21, and then sends it to another working unit 1, and winds it using a segmented winding method at another working unit 1. Finally, the material transfer device 22 clamps the wound magnetic ring for unloading.

[0083] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structure made using the contents of the present invention's specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. An inductor winding method, characterized in that: The winding method is based on a winding device, wherein the winding device comprises at least one group of working units (1), wherein the working unit (1) comprises a wire feeding mechanism (2), a positioning mechanism (3) and a winding mechanism (4), wherein the positioning mechanism (3) comprises a magnetic ring clamp (5) and a flipping drive (6) for driving the magnetic ring clamp (5) to flip 180 degrees; The inductor winding method comprises: Step S1: According to a preset winding length, controlling the wire feeding mechanism (2) to feed a certain length of winding wire to the magnetic ring, the winding length being less than the preset winding length; Step S2: controlling the winding mechanism (4) to wind the winding wire end around the winding portion of the magnetic ring to form a first winding, and after the winding mechanism (4) completes winding of one circle of the winding portion, the winding mechanism (4) moves a preset distance in the circumferential direction of the winding portion, so that each circle of winding can be arranged in sequence on the winding portion; Step S3: Control the winding mechanism (4) to reset along the circumferential direction of the winding portion, and the flipping drive (6) drives the magnetic ring clamp (5) to flip 180°; Step S4: controlling the winding mechanism (4) to wind the winding wire tail onto the winding portion of the magnetic ring to form a second winding, and after the winding mechanism (4) completes winding of one turn of the winding portion, the winding mechanism (4) moves a preset distance along the circumferential direction of the winding portion, so that each turn of the winding wire can be arranged in sequence on the winding portion; In step S1, the wire feeding mechanism (2) is controlled to feed half the length of the winding wire or three quarters of the length of the winding wire to the magnetic ring; When the wire feeding mechanism (2) feeds half the length of the winding wire to the magnetic ring, the first winding is wound in the same manner as the second winding; The first winding and the second winding are single-layer windings or double-layer windings; The winding mechanism (4) comprises a winding device (7), a hook device (8) and a rotation drive (9) for driving the winding device (7) and the hook device (8) to rotate along the circumferential direction of the winding portion; The control winding mechanism (4) winds the winding wire head and the winding wire tail on the winding part of the magnetic ring, specifically comprising: For each winding, the winding device (7) is controlled to flip the winding below the magnetic ring to the top of the magnetic ring and place it horizontally, and the hook device (8) is controlled to extend from the center of the magnetic ring to hook the winding from the top of the magnetic ring to the bottom of the magnetic ring to complete a winding. The winding device (7) comprises a winding drive (10) and a winding rod (11) eccentrically connected to the output end of the winding drive (10), wherein the winding rod (11) has a winding wheel (12) capable of clamping the winding wire; Then the control winding device (7) turns the winding below the magnetic ring to above the magnetic ring and places it horizontally, specifically comprising: The winding drive (10) is controlled to drive the winding rod (11) to make an eccentric movement at the magnetic ring, driving the winding wheel (12) to hook the wire from the bottom of the magnetic ring, then retract and rise again to turn over and wind the wire to the top of the magnetic ring.

2. The inductor winding method according to claim 1, characterized in that: The winding mechanism (4) further comprises an infrared counter arranged at the winding device (7), and the infrared counter is used to sense and record the number of winding turns completed by the winding device (7).

3. The inductor winding method according to claim 1, characterized in that: The rotary drive (9) comprises a mounting frame (13), a rotary motor (14), a transmission cylinder (15) rotatably arranged on the mounting frame (13), and a gear set (16) for transmission connection between the rotary motor (14) and the transmission shaft; the winding device (7) and the hook device (8) are fixed on the transmission cylinder (15).

4. The inductor winding method according to claim 1, characterized in that: The winding device comprises two groups of working units (1), and a transfer device (21) and a material transfer device (22) arranged between the two groups of working units (1), wherein the material transfer device (22) can drive the magnetic ring to move between the working unit (1) and the transfer device (21); The inductor winding method further comprises: Controlling the material transfer device (22) to transfer the magnetic ring wound by one of the working units (1) to the transfer device (21); Controlling the transfer device (21) to rotate 180°; The material transfer device (22) is controlled to transfer the magnetic ring at the transfer device (21) to another working unit (1).

5. The inductor winding method according to claim 1, characterized in that: The winding equipment also includes a magnetic ring automatic feeding device (20).

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