A winding device, a winding method for manufacturing a small-sized coil assembly, and a small-sized square coil assembly

Abstract

A winding device, coil assembly includes at least two layers of multi-turn winding wire, comprising: coil frame, wire feeding mechanism, limiting guide mechanism and winding control unit; Coil frame includes frame shaft, first side stop, second side stop; Wire feeding mechanism, coil frame and limiting guide mechanism movement and state are controlled by winding control unit, from the first side stop winding, until from the second side stop, from the second side stop winding, reciprocate until the coil winding is completed; Wire feeding mechanism makes a circular motion relative to the coil frame during winding, forming at least two layers of multi-turn winding wire; Limiting guide mechanism includes limiting baffle and baffle support part, limiting baffle is arranged between both ends of coil frame, configured to move between first side stop and second side stop controlled by winding control unit, in the winding process, sequentially contact and press at least first layer of each turn of wire, resist the sliding tendency of wire along the winding tension and limit.

Description

Technical Field

[0001] This invention relates to a winding apparatus, a winding method, and a small-sized square coil assembly for manufacturing small-sized coil assemblies. Background Technology

[0002] Coils are fundamental components in many electronic products, and their performance often directly affects the electrical performance of electronic products. Generally speaking, neat, compact, and consistent coil windings will improve the electrical performance of electronic products.

[0003] Taking the application of coils in motors as an example, the coils in motors are often racetrack-shaped, rounded rectangular, or rectangular, and are placed in the narrow space between the teeth of the motor core, such as... Figure 1 As shown, electromagnetic force is generated by coils. The small space where the coils are placed is called a stator slot, and the area of ​​the stator slot occupied by the cross-sectional area of ​​the conductors in the coil winding is called the slot fill factor. The slot fill factor has a significant impact on the performance of the motor. Specifically, firstly, a motor with a high slot fill factor produces greater torque for the same copper losses (i.e., DC ohmic losses of the conductors in the motor); secondly, a high slot fill factor means that the copper wires are densely packed, which is beneficial for heat conduction between conductors and between conductors and the iron core or other components of the motor, thereby improving the motor's heat dissipation capacity.

[0004] In a motor coil, the conductors that perform mechanical work are those along the axial direction of the motor, while the conductors at the ends along the tangential direction of the motor axis do not. Therefore, for an ideal coil, the cross-section of the conductors along the axial direction of the motor should be arranged in a planar, densest arrangement; that is, the long side of the coil should be arranged in a planar, densest arrangement. For a coil made of round wire, the optimal arrangement is as follows: Figure 2 As shown, this is the densest arrangement in a plane, and such windings are also called orthocyclic windings, which can occupy up to 90.7% of the space.

[0005] Furthermore, since coils are often wound in multiple layers and in a spiral pattern, during the winding process, there will inevitably be a point where the wires of one layer intersect with the next. If the long side of the coil is to be arranged in the most dense planar manner, then the intersecting points, such as... Figure 3 As shown, it must be located on the shorter side.

[0006] Therefore, having as Figure 2 and Figure 3 The coil with the characteristics shown can be considered an ideal motor coil.

[0007] However, the ideal coil described above presents numerous difficulties in actual winding, especially in small-sized square coils. Specifically, the following challenges need to be overcome:

[0008] First, the stiffness of a conductor is directly proportional to its cross-sectional area, meaning it increases quadratically with the conductor diameter. When the conductor is embedded in the groove between two turns, it relies on the frictional force created by the groove, which is also proportional to the conductor diameter. Therefore, as the conductor diameter increases, the conductor stiffness increases, making the winding easier to shape and preventing misalignment. Simultaneously, the frictional force of the groove on the conductor also increases, making it easier for the conductor to be stably positioned within the groove. For small-sized square coils, the diameter of the wound conductor is small, resulting in poor conductor stiffness and making it susceptible to deformation or displacement due to external forces. Furthermore, the frictional force from the groove is small, making it very easy for the conductor to slip out of the pre-designed groove during winding.

[0009] Second, such as Figure 4 As shown, since an ideal coil requires the intersection of the two layers of winding to be located on the short side, the coil wire will have a diagonal crossing at the short side, with a crossing angle of θ = arcsin(wire diameter / short side length). The tension F of the wire will then decompose at the crossing angle θ to generate a vertical component force Fsinθ. For small-sized square coils, the short side length is small, while the crossing angle is large, resulting in a larger vertical component force. This vertical component force is transmitted along the wire, causing the wire to detach from the groove on the long side in the vertical direction. The shorter the short side length, the larger the crossing angle, the larger the vertical component force, and the easier it is to detach from the groove on the long side, or directly detach from the preset parallel path on the first layer of the long side.

[0010] Third, ideal coils have extremely high consistency requirements. If one turn is wrong, the subsequent coils will be disordered, causing the entire coil to be scrapped. In addition to the reasons mentioned above, due to its small overall size, the coil is easily affected by the external environment during the winding process, resulting in a high scrap rate.

[0011] To address the aforementioned problems, existing winding devices typically employ the following solutions in an attempt to resolve these technical issues:

[0012] 1. Wind the coil wire onto the bobbin, such as... Figure 5 As shown, by using limiting mechanisms on the skeleton, such as grooves, the coil wires and the skeleton will not separate during the winding process, so as to achieve stable and reliable winding, and the coil and skeleton are fitted onto the motor core.

[0013] However, due to the presence of the skeleton itself, this solution is difficult to separate from the coil after winding, which will occupy a lot of space in motor applications, thus negating the advantages brought by the densest arrangement. If the skeleton is separated from the coil through structural or process design after winding, it will increase the production cost.

[0014] Second, a circular coil is first formed by winding, and then a square coil is formed by extruding the coil. However, this method requires additional process steps, resulting in higher production costs. In addition, the extrusion process can easily cause significant deformation and physical damage to the wound coil. Summary of the Invention

[0015] In view of this, the present invention proposes a winding device, winding method and small square coil assembly for manufacturing small-sized coil assemblies, which can achieve the winding of ideal coils without adding extra process steps. It can not only solve the defects of the original coil assembly and improve the electrical performance of square coils, but also achieve the characteristics of easy production and manufacturing.

[0016] The technical solution for the winding device for manufacturing small-sized coil assemblies provided by this invention specifically includes:

[0017] A winding device for winding a small-sized coil assembly using wire, the coil assembly comprising at least two layers of multi-turn wound wire, the winding device comprising: a coil frame, a wire feeding mechanism, a limiting and guiding mechanism, and a winding control unit;

[0018] The coil frame includes a central axis, a first side flange, and a second side flange;

[0019] The movement and state of the wire feeding mechanism, the coil frame, and the limiting guide mechanism are controlled by the winding control unit, so that the wire starts to wind from the first side stop of the coil frame, until it starts to wind from the second side stop, and then starts to wind from the second side stop again, repeating until the coil winding is completed;

[0020] During the winding process, the wire feeding mechanism makes a circular motion relative to the coil frame, thereby forming at least two layers of multi-turn wound wire around the coil frame;

[0021] The limiting guide mechanism includes a limiting baffle and a baffle support. The limiting baffle is disposed between the two ends of the coil frame and is configured to be controlled by the winding control unit to move between the first side stop and the second side stop of the coil frame, thereby contacting and pressing each turn of the conductor in at least the first layer in sequence during the winding of the coil assembly, and limiting the conductor against the sliding tendency of the conductor caused by the winding tension.

[0022] Preferably, the limiting guide mechanism is disposed on the outside of the wound coil assembly, the first side stop and / or the second side stop are provided with grooves, the limiting guide mechanism is movably disposed in the grooves, and the limiting guide mechanism is adapted to move in directions away from and towards the coil frame.

[0023] Preferably, the limiting guide mechanism is disposed on the inner side of the wound coil assembly, and the central shaft of the skeleton, the first side stop, and the second side stop are all provided with grooves for the limiting guide mechanism to slide, and the limiting guide mechanism is movably disposed in the grooves.

[0024] Preferably, the limiting guide mechanism is disposed on the inner side of the wound coil assembly, and the central shaft of the skeleton and the second side stop are both provided with grooves for the limiting guide mechanism to slide, and the limiting guide mechanism is movably disposed in the grooves.

[0025] Preferably, the first side stop and / or the second side stop are detachably connected to the central axis of the frame, and the coil frame is adapted to move relative to the coil in the direction from the first side stop to the second side stop.

[0026] Preferably, the winding device further includes a wire guide mechanism, which is disposed on the coil frame and is used to guide the wire inlet of the coil assembly.

[0027] Preferably, the winding device further includes a detection system, which includes one or more sensing units configured to detect in real time during the winding of the coil assembly and provide feedback to the winding control unit on whether the winding path of the conductor conforms to a preset path.

[0028] Preferably, the sensing unit includes at least one of a visible light vision system, radar, infrared sensor, and ultrasonic sensor.

[0029] The present invention also provides a method for winding a small-sized coil assembly using the winding device described in any of the foregoing claims, comprising the following steps:

[0030] In the wire feeding step, the winding control unit controls the wire feeding mechanism to feed the wire near the first side stop.

[0031] In the winding step, the winding control unit controls the wire feeding mechanism to perform relative circumferential motion around the coil frame; at the same time, the limiting and guiding mechanism restricts the running path of the wire.

[0032] The next step is to remove the coil assembly from the coil frame.

[0033] Preferably, the winding step further includes:

[0034] The wire feeding mechanism forms the first long side of the first turn of the coil assembly.

[0035] The wire feeding mechanism performs a relative circumferential motion around the coil frame, forming the second long side of the coil assembly. Simultaneously, the limiting baffle of the limiting guide mechanism applies pressure to the coil assembly in the stacking direction of the coil assembly, restricting the slippage of the wire due to tension.

[0036] The wire feeding mechanism moves relative to the coil frame to form the first long side of the next turn, while the limiting baffle of the limiting guide mechanism moves to make room for the next turn.

[0037] Preferably, the removal step further includes: separating the first side stop or the second side stop from the coil frame, and separating the coil assembly from the coil frame.

[0038] In addition, the present invention also provides a small-sized square coil assembly, the coil assembly including an inlet, a coil body, and an outlet, which is made of a wire with a circular cross-section.

[0039] The coil body is formed by winding the wire from the inside out, including N layers, i.e., 1...K...N, where N is greater than or equal to 2;

[0040] Each layer of the conductor contains several turns, and each turn of the conductor is wound along the first long side, the first short side, the second long side, and the second short side of the coil body in sequence during the winding process;

[0041] Its features are,

[0042] In the first long side and the second long side, the wire of the K+1th layer is embedded in the gap formed by the adjacent wires of the Kth layer;

[0043] In the first short side and the second short side, at least one of the short sides has its K+1 layer wires intersecting with the K layer wires in an X-shape, where 1≤K≤N-1.

[0044] Preferably, in the X-shaped interleaving, the number of interleaved wires between the (K+1)th layer wire and the Kth layer wire is 2.

[0045] Preferably, a cavity is formed inside the coil body, the cavity includes a long side and a short side, and the length of the long side is greater than or equal to twice the length of the short side.

[0046] Preferably, a cavity is formed inside the coil body, the cavity includes a long side and a short side, and the length of the short side is greater than or equal to twice the diameter of the conductor.

[0047] Preferably, the length of the short side of the cavity is 3-15 times the diameter of the wire.

[0048] Preferably, a cavity is formed inside the coil body, the cavity includes a long side and a short side, the length of the short side is greater than or equal to 1 mm and less than or equal to 5 mm, and the diameter of the wire is greater than or equal to 0.1 mm and less than or equal to 1.0 mm.

[0049] By applying the winding device, winding method, and small-sized square coil assembly proposed in this invention, the problems existing in the prior art can be solved from the source, bringing the following advantages:

[0050] First, the winding apparatus and method provided by this invention can effectively wind small coils that are neat, tightly arranged, and highly consistent. In particular, it can wind the coil assemblies provided by this invention with high efficiency and high consistency. Compared with wild winding, the winding apparatus and method provided by this disclosure can increase the fill rate of hollow coils by more than 100%; compared with ordinary wound hollow coils, it can increase it by 10%-20%.

[0051] Secondly, the winding device and winding method provided by the present invention have good consistency, high yield, and low cost, and can effectively improve the performance of various electrical components such as small motors, inductors, and small transformers without significantly increasing costs.

[0052] Third, the coil assembly provided by this invention features a compact arrangement, which significantly improves the space utilization of electrical devices. Compared with the existing hollow coils with tightly arranged long sides, the size is significantly reduced, and it has a smaller short side. The compact arrangement of small-sized coils with a small short side makes it possible to manufacture devices such as small motors and transformers with high slot fill factor and high efficiency.

[0053] Fourth, the coil assembly provided by the present invention has specific wire diameter and short side length, size, ratio and interlacing method. On the one hand, the upper limit makes the short side of the coil cross-wire angle smaller, corresponding to a smaller vertical component of the tension, thus having practical winding capability. On the other hand, the lower limit ensures that the wire diameter is not too small, which would cause winding difficulties.

[0054] These and other objects and advantages will become more apparent to those skilled in the art after reading the following sections of this specification in conjunction with the accompanying drawings. Attached Figure Description

[0055] The above-described invention and the following detailed description will be better understood when read in conjunction with the accompanying drawings. It should be noted that the drawings are merely examples of the claimed invention. In the drawings, the same reference numerals represent the same or similar elements.

[0056] Figure 1 The diagram shows a coil structure installed in the stator slot of a motor in the prior art;

[0057] Figure 2 The diagram shows a schematic of an ideal coil cross-section conductor arrangement.

[0058] Figure 3 The diagram shown is a schematic of an ideal coil conductor structure;

[0059] Figure 4 The diagram shown is a schematic of an ideal coil with a slanted cross-wire structure.

[0060] Figure 5 The diagram shown is a schematic diagram of a winding device for manufacturing small-sized coil assemblies according to an embodiment of the present invention.

[0061] Figure 6 The figure shown is an exploded view of the coil frame and the limiting guide mechanism in a winding device provided in an embodiment of the present invention;

[0062] Figure 7 The diagram shown is a schematic representation of the moving direction of a limiting and guiding mechanism for manufacturing small-sized coil assemblies according to an embodiment of the present invention.

[0063] Figure 8 The diagram shown is a schematic diagram of the winding direction of a winding device for manufacturing small-sized coil assemblies according to an embodiment of the present invention.

[0064] Figure 9 The diagram shown is a schematic representation of the coil frame and the limiting and guiding mechanism in the winding device provided in the second embodiment of the present invention.

[0065] Figure 10 The figure shown is an exploded view of the coil frame and the limiting guide mechanism in the winding device provided in the second embodiment of the present invention;

[0066] Figure 11 The diagram shown is a schematic representation of the coil frame and the limiting and guiding mechanism in the winding device provided in the third embodiment of the present invention.

[0067] Figure 12 The figure shown is an exploded view of the coil frame and the limiting guide mechanism in the winding device provided in the third embodiment of the present invention;

[0068] Figure 13 The diagram shown is a structural schematic of a small-sized coil assembly according to an embodiment of the present invention;

[0069] Figure 14 The image shown is a top view of a small-sized coil assembly along the winding direction according to an embodiment of the present invention;

[0070] Figure 15 The image shown is a side view along the short side of a small-sized coil assembly according to an embodiment of the present invention;

[0071] Figure 16 The diagram shown is a structural schematic of a small-sized coil assembly cavity provided in an embodiment of the present invention;

[0072] The attached figures are labeled as follows:

[0073] 100. Coil Assembly

[0074] 110. Cable Inlet

[0075] 120. Coil body

[0076] 121. The first longest side

[0077] 122. The second longest side

[0078] 123. First short side

[0079] 124. Second shorter side

[0080] 130. Cable Outlet

[0081] 140. X-shaped interlacing

[0082] 150. Cavity

[0083] 151. Long side of the cavity

[0084] 152. Short side of the cavity

[0085] 200, 200a, 200b, winding device

[0086] 210, 210a, 210b, coil frame

[0087] 211, 211a, 211b, central axis of the skeleton

[0088] 212, 212a, 212b, First side retaining edge

[0089] 213, 213a, 213b, Second side flange

[0090] 214. Baffle connection part

[0091] 220, 220a, 220b, wire feeding mechanism

[0092] 230, 230a, 230b, Limiting and guiding mechanisms

[0093] 231, 231a, 231b, Limit baffle

[0094] 232, 232a, 232b, Limiting baffle support unit

[0095] 240, 240a, 240b, Line entry guidance mechanism

[0096] 250, 250a, 250b, Groove Detailed Implementation

[0097] The following detailed description of the features and advantages of the present invention is sufficient to enable any person skilled in the art to understand the technical content of the present invention and implement it accordingly. Furthermore, based on the specification, claims and drawings disclosed herein, those skilled in the art can easily understand the related objects and advantages of the present invention.

[0098] Figures 5-8 A preferred embodiment of the winding apparatus for manufacturing small-sized coil assemblies provided by the present invention is shown.

[0099] Figure 5 and Figure 6 The main component structure of the winding device 200 for manufacturing small-sized coil assemblies provided by the present invention is shown, including:

[0100] The coil frame 210, the wire feeding mechanism 220, the limiting and guiding mechanism 230, and the winding control unit (not shown in the figure) are included.

[0101] The coil frame 210 is used to support the coil assembly 100 during the winding process. It includes a frame central axis 211, a first side guard 212, and a second side guard 213. The coil assembly 100 is wound around the outside of the frame central axis 211. The first side guard 212 and the second side guard 213 are located on both sides of the coil assembly 100 on the frame central axis 211 in the stacking direction, respectively, and play a role in limiting the size of the coil assembly 100 in the stacking direction during the winding process.

[0102] The limiting guide mechanism 230 includes a connected limiting baffle 231 and a limiting baffle support 232. The limiting baffle 231 is disposed between the two ends of the coil frame 210. The limiting baffle 231, facing the stacking direction of the coil assembly 100, can exert pressure on the winding wire. The limiting baffle 231 acts on the second long side 122 of the coil assembly 100. The limiting baffle support 232 connects the power drive (not shown) that drives the limiting guide mechanism and the limiting baffle 231. The limiting baffle 231 is configured to be controlled by the winding control unit to move between the first side stop 212 and the second side stop 213 of the coil frame 210, thereby contacting and applying pressure to each turn of the wire in at least the first layer during the winding process of the coil assembly 100, resisting the slippage tendency of the wire caused by the winding tension, and limiting the wire.

[0103] In some preferred embodiments, the limiting guide mechanism 230 is disposed inside the wound coil assembly 100, and the frame central shaft 211, the first side stop 212, and the second side stop 213 are all provided with grooves 250 with the same cross section, and the limiting guide mechanism 230 is movably disposed in the grooves 250.

[0104] It is understood that in some other embodiments, the central axis 211 of the skeleton and the second side flange 213 are both provided with grooves with the same cross section.

[0105] In some preferred embodiments, the limiting baffle 231 is smaller than the cavity 150 inside the coil assembly 100, so that the coil assembly 100 is not interfered with during the process of detaching from the coil frame 210.

[0106] In some preferred embodiments, the limiting baffle 231 is a complete planar baffle that makes line contact with the coil during the winding process.

[0107] In some preferred embodiments, the limiting baffle 231 may also be an inverted V-shape, a wave shape, or other shapes that can restrict the sliding of the wire.

[0108] The limiting and guiding mechanism 230 limits the direction of the conductor's sliding tendency caused by the winding tension during the winding of one or several layers or all layers of the coil assembly 100, guiding the conductor's path so that it runs along the defined path. During the winding process, in most cases, part of the limiting baffle support 232 is located within the cavity 150 inside the coil assembly 100. However, there are a few time periods or specific stages of winding where the limiting baffle support 232 is completely outside the cavity 150 inside the coil assembly 100. Because the limiting baffle 231 needs to contact the coil, it has a portion extending to the outside of the coil assembly 100.

[0109] In some preferred embodiments, the limiting baffle applies pressure to the coil immediately after each turn of the second long side 122 of the first layer of the coil assembly, which can effectively limit the cross-wire force of the coil assembly 100 during the winding process.

[0110] The winding control unit controls the movement and state of the wire feeding mechanism 220, the coil frame 210, and the limiting and guiding mechanism 230. Specifically, the winding control unit controls the relative movement between the wire feeding mechanism 220 and the coil frame 210, so that the wire is wound from the first side stop 212 of the coil frame 210 until it starts winding from the second side stop 213, and then from the second side stop 213 again, repeating until the coil assembly 100 is wound.

[0111] The winding control unit simultaneously controls the movement of the limiting baffle 231 between the first side baffle 212 and the second side baffle 213 of the coil frame 210. During the winding process of one or more layers of the coil assembly 100, the limiting baffle 231 limits the sliding tendency of the conductor caused by the winding tension.

[0112] In some preferred embodiments, the winding control unit may consist of one or more microcontrollers, PLCs, computers, or other units capable of processing signals and executing winding logic commands.

[0113] In some preferred embodiments, the winding device 200 further includes a wire guide mechanism 240, which is disposed on the coil frame 210 near the first side flange 212, for guiding the wire inlet of the coil assembly 100. The wire feeding mechanism 220 feeds the wire into and winds it onto the central shaft 211 of the frame by guiding it. During the winding process, the wire inlet of the coil is formed at the wire guide mechanism.

[0114] In some preferred embodiments, the wire guide mechanism 240 is a groove disposed on the first or second side stop, extending away from the coil along the long side of the coil assembly 100, through which the wire enters the coil frame 210. In some preferred embodiments, the wire guide mechanism 240 is disposed on the first side stop 212 and has an oblique opening shape, with the wire inlet of the coil assembly 100 formed within the groove.

[0115] In some preferred embodiments, the lead guide mechanism 240 may be a tunnel or a tension mechanism, which uses tension to shape the conductor and complete the guidance.

[0116] In some preferred embodiments, the first side guard 212 and / or the second side guard 213 are detachably connected to the central axis 211 of the frame. The central axis 211 of the frame is connected to the second side guard 213 or the first side guard 212 through the baffle connecting part 214. The baffle connecting part 214 is completely within the extended space of the cavity 150 inside the coil assembly 100, which allows the coil assembly 100 to be easily separated from the coil frame 210 without interference.

[0117] In some preferred embodiments, during the winding process of the coil assembly 100, the second side flange 213 is connected to the central axis 211 of the frame, and the second side flange 213 and the first side flange 212 limit the coil assembly 100. After winding is completed, the second side flange 213 separates from the central axis 211 of the frame, and the coil assembly 100 disengages from the second side flange 213. In some preferred embodiments, the connection between the second side flange and the frame can be achieved by screws, tenons, shaft hole fittings, snap fasteners, etc.

[0118] Figure 7The diagram illustrates the movement of the limiting guide mechanism 230 during the winding process. Under the action of a power drive (not shown in the figure), the limiting guide mechanism 230 can be controlled and positioned at any position between the first side stop 212 and the second side stop 213, along the stacking direction of the coil assembly 100.

[0119] In some preferred embodiments, the power drive can consist of a power source with active driving capability, such as a pneumatic actuator, a servo motor, or a hydraulic actuator, and its corresponding transmission mechanism.

[0120] Figure 8 The diagram shows the relative motion trajectory between the wire feeding mechanism 220 and the coil frame 210 during the winding process. During winding, the wire feeding mechanism 220 makes a relative circumferential motion around the coil frame 210. The circumferential motion can be circular motion or other motions that constitute the encircling trajectory as needed. The circumferential motion can be selected in a clockwise or counterclockwise direction as needed.

[0121] In some preferred embodiments, the relative movement of the wire feeding mechanism 220 around the coil frame 210 can be that the wire feeding mechanism 220 is stationary and the coil frame 210 is moving; or the wire feeding mechanism 220 is moving and the coil frame 210 is stationary; or the wire feeding mechanism 220 and the coil frame 210 are linked.

[0122] Figures 9-12 Two other preferred embodiments of the winding apparatus for manufacturing small-sized coil assemblies provided by the present invention are shown.

[0123] Figures 9-10 A preferred embodiment of the winding apparatus for manufacturing small-sized coil assemblies provided by the present invention is shown, wherein a limiting guide mechanism 230a is disposed on the outer side of the coil assembly 100 to be wound, and a second side stop 213a is provided with a groove 250a, in which the limiting guide mechanism 230a is movably disposed. A wire entry guide mechanism 240a is disposed on the first side stop 212a.

[0124] In some preferred embodiments, the limiting guide mechanism 230a can move away from and towards the groove of the second side flange 213a in the direction of coil assembly 100 stacking. The second side flange 213a is detachably connected to the central axis 211a of the frame.

[0125] Figures 11-12 This invention illustrates another preferred embodiment of the winding apparatus for manufacturing small-sized coil assemblies, wherein a limiting guide mechanism 230b is disposed on the outer side of the coil assembly 100 to be wound, and a second side stop 213b is provided with a groove 250b, in which the limiting guide mechanism 230b is movably disposed. A wire entry guide mechanism 240b is disposed on the first side stop 212b.

[0126] In some preferred embodiments, the limiting guide mechanism 230b is movable in the direction of the coil assembly 100 stacking, away from and towards the groove of the second side flange 213b. The first side flange 212b is detachably connected to the central axis 211b of the frame.

[0127] In some preferred embodiments, the limiting guide mechanism is disposed on the outside of the wound coil assembly, and both the first side stop and the second side stop are provided with grooves with the same cross section.

[0128] In some preferred embodiments, the winding device 200 further includes a detection system comprising one or more sensing units, which may include a visible light vision system, radar, infrared sensors, ultrasonic sensors, etc. It is configured to detect in real time during the winding of the coil assembly and provide feedback to the winding control unit on whether the winding path of the conductor conforms to a preset path. By way of example and not limitation, when a deviation in the winding path of the inverted coil is detected, the winding control unit may control the winding device 200 to interrupt the current coil winding or rewind it for re-winding.

[0129] The present invention also provides a method for winding a small-sized coil assembly using any of the winding devices provided by the present invention, comprising the following steps:

[0130] In the wire feeding step, the wire feeding mechanism 220, controlled by the winding control unit, feeds the wire into the winding mechanism near the first side stop 212.

[0131] In the winding process, the winding control unit controls the wire feeding mechanism 220 to perform relative circular motion around the coil frame 210; at the same time, the limiting and guiding mechanism 230 restricts the running path of the wire.

[0132] Next, remove the coil assembly 100 from the coil frame 210.

[0133] In some preferred embodiments, the winding step further includes,

[0134] The wire feeding mechanism 220 forms the first long side 121 of the first turn of the coil assembly 100.

[0135] The wire feeding mechanism 220 moves relative to the coil frame 210 to form the second long side 122 of the coil assembly 100. At the same time, the limiting baffle 231 of the limiting guide mechanism 230 applies pressure to the coil assembly 100 in the stacking direction of the coil assembly 100 to limit the slippage of the wire caused by tension.

[0136] The wire feeding mechanism 220 moves relative to the coil frame 210 to form the first long side 121 of the next turn. At the same time, the limiting baffle 231 of the limiting guide mechanism 230 moves to leave space for the next turn.

[0137] In some preferred embodiments, the removal step further includes separating the second side flange 213 from the coil frame 210 and separating the coil assembly 100 from the coil frame 210.

[0138] Figures 13-16 This invention illustrates a small-sized square coil assembly 100, which is wound using any of the winding devices provided by this invention.

[0139] The coil assembly 100 includes an inlet 110, a coil body 120, and an outlet 130, and is made of a wire with a circular cross-section. The coil body 120 has a cavity 150 inside, which includes a long side 151 and a short side 152.

[0140] The coil body 120 is formed by winding wires sequentially from the inside out, including N layers, i.e., 1...K...N, where N is greater than or equal to 2. It is understood that in some preferred embodiments, such as... Figure 13 , Figure 14 As shown, N = 4.

[0141] Each layer of wire contains several turns. During the winding process, each turn of wire is wound along the first long side 121, the first short side 123, the second long side 122 and the second short side 124 of the coil body 120 to form a generally rectangular cross-sectional shape.

[0142] In some preferred embodiments, due to factors such as actual manufacturing limitations or application scenarios, the coil body 120 is in the shape of a rounded rectangle, a racetrack shape, an ellipse, or a rounded rectangle that is close to an ellipse, which is close to a square shape.

[0143] In the first long side 121 and the second long side 122, the wire of the K+1 layer is embedded in the gap (recess) formed by the adjacent wire of the K layer;

[0144] In the first short side 123 and the second short side 124, at least one of the short sides forms an X-shaped crossover 140 with the conductor of the K+1 layer and the conductor of the K layer, where 1≤K≤N-1.

[0145] In some preferred embodiments, in the X-type crossover 140, the number of crossover bridging wires between the conductors of layer K+1 and the conductors of layer K is 2. Of course, other numbers of bridging wires are also possible as needed.

[0146] In some preferred embodiments, the length of the long side 151 of the cavity is greater than or equal to twice the length of the short side 152 of the cavity.

[0147] In some preferred embodiments, the length of the short side 152 of the cavity is greater than or equal to twice the diameter of the wire, preferably three to 15 times.

[0148] In some preferred embodiments, the length of the short side 152 of the cavity is greater than or equal to 1 mm and less than or equal to 5 mm, and the diameter of the wire is greater than or equal to 0.1 mm and less than or equal to 1.0 mm.

[0149] like Figure 13 In one embodiment of the present invention, the coil assembly 100 is wound in a left-handed spiral. In some preferred embodiments, the winding direction may also be a right-handed spiral, depending on the application scenario.

[0150] As can be seen from the above embodiments, the winding device and method for manufacturing small-sized coil assemblies provided by the present invention can effectively wind small coils that are neat, tightly arranged, and highly consistent. In particular, it can wind the coil assemblies provided by the present invention with high efficiency and high consistency. Compared with messy winding, the winding device and method provided by this disclosure can increase the filling rate of hollow coils by more than 100%; compared with ordinary wound hollow coils, it can increase it by 10%-20%; it has good consistency, high yield, and low cost, and can effectively improve the performance of various electrical components such as small motors, inductors, and small transformers without significantly increasing costs.

[0151] This invention provides a small-sized square coil assembly with a compact arrangement, which significantly improves the space utilization of electrical devices. Compared with the existing hollow coils with tightly arranged long sides, the size is significantly reduced, and it has a smaller short side. The compact arrangement of small-sized coils with a small short side makes it possible to manufacture devices such as small motors and transformers with high slot fill factor and high efficiency. With specific wire diameter, short side length, size, ratio, and interlacing pattern, on the one hand, the upper limit allows for a small cross-angle of the short side of the coil, corresponding to a small vertical component of the tension, thus providing practical winding capability; on the other hand, the lower limit prevents the wire diameter from being too small, which would cause winding difficulties.

[0152] The terminology and expressions used herein are for descriptive purposes only, and the invention should not be limited to these terms and expressions. The use of these terms and expressions does not imply the exclusion of any illustrative and descriptive equivalent features (or parts thereof), and it should be recognized that various modifications that may exist should also be included within the scope of the claims. Other modifications, variations, and substitutions may also exist. Accordingly, the claims should be considered to cover all such equivalents.

[0153] Similarly, it should be noted that although the present invention has been described with reference to the specific embodiments described above, those skilled in the art should recognize that the above embodiments are only used to illustrate the present invention, and various equivalent changes or substitutions can be made without departing from the spirit of the present invention. Therefore, any changes or modifications to the above embodiments within the scope of the essential spirit of the present invention will fall within the scope of the claims of this application.

Claims

1. A winding device for winding a small-sized coil assembly using wire, the coil assembly comprising at least two layers of multi-turn wound wire, the winding device comprising: Coil frame, wire feeding mechanism, limit and guide mechanism, and winding control unit; The coil frame includes a central axis, a first side flange, and a second side flange; The movement and state of the wire feeding mechanism, the coil frame, and the limiting guide mechanism are controlled by the winding control unit, so that the wire starts to wind from the first side stop of the coil frame, until it starts to wind from the second side stop, and then starts to wind from the second side stop again, repeating until the coil winding is completed; During the winding process, the wire feeding mechanism makes a circular motion relative to the coil frame, thereby forming at least two layers of multi-turn wound wire around the coil frame; Its features are, The limiting guide mechanism includes a limiting baffle and a baffle support. The limiting baffle is disposed between the two ends of the coil frame and is configured to be controlled by the winding control unit to move between the first side stop and the second side stop of the coil frame, thereby contacting and pressing each turn of the conductor in at least the first layer in sequence during the winding of the coil assembly, and limiting the conductor against the sliding tendency of the conductor caused by the winding tension.

2. The winding device as described in claim 1, characterized in that, The limiting guide mechanism is disposed on the outside of the wound coil assembly. The first side stop and / or the second side stop are provided with grooves. The limiting guide mechanism is movably disposed in the grooves. The limiting guide mechanism is adapted to move in directions away from and towards the coil frame.

3. The winding device as described in claim 1, characterized in that, The limiting guide mechanism is disposed on the inner side of the wound coil assembly. The central shaft of the skeleton, the first side stop, and the second side stop are all provided with grooves for the limiting guide mechanism to slide. The limiting guide mechanism is movably disposed in the grooves.

4. The winding device as described in claim 1, characterized in that, The limiting guide mechanism is disposed on the inner side of the wound coil assembly. The central shaft of the skeleton and the second side stop are both provided with grooves for the limiting guide mechanism to slide. The limiting guide mechanism is movably disposed in the grooves.

5. The winding device as described in claim 1, characterized in that, The first side stop and / or the second side stop are detachably connected to the central axis of the frame, and the coil frame is adapted to move relative to the coil in the direction from the first side stop to the second side stop.

6. The winding device according to any one of claims 1-5, characterized in that, The winding device further includes a wire guide mechanism, which is disposed on the coil frame and is used to guide the wire inlet of the coil assembly.

7. The winding device according to any one of claims 1-5, characterized in that, The winding device further includes a detection system comprising one or more sensing units configured to detect in real time during the winding of the coil assembly and provide feedback to the winding control unit on whether the winding path of the conductor conforms to a preset path.

8. The winding device as described in claim 7, characterized in that, The sensing unit includes at least one of a visible light vision system, radar, infrared sensor, and ultrasonic sensor.

9. A winding method for winding a small-sized coil assembly using the winding apparatus as described in any one of claims 1-5, characterized in that, Includes the following steps: In the wire feeding step, the winding control unit controls the wire feeding mechanism to feed the wire near the first side stop. In the winding step, the winding control unit controls the wire feeding mechanism to perform relative circumferential motion around the coil frame; at the same time, the limiting and guiding mechanism restricts the running path of the wire. The next step is to remove the coil assembly from the coil frame.

10. The winding method as described in claim 9, characterized in that, The winding step further includes: The wire feeding mechanism forms the first long side of the first turn of the coil assembly. The wire feeding mechanism moves relative to the coil frame, forming the second long side of the coil assembly. Simultaneously, the limiting baffle of the limiting guide mechanism applies pressure to the coil assembly in the stacking direction of the coil assembly, restricting the slippage of the wire due to tension. The wire feeding mechanism performs a relative circling motion around the coil frame to form the first long side of the next turn, while the limiting baffle of the limiting guide mechanism moves to leave space for the next turn.

11. The winding method as described in claim 9, characterized in that, The removal step further includes: separating the first side stop or the second side stop from the coil frame, and separating the coil assembly from the coil frame.

12. A small-sized square coil assembly wound using the winding device as described in any one of claims 1-5, the coil assembly comprising an inlet, a coil body, and an outlet, and wound from a wire with a circular cross-section; The coil body is formed by winding the wire from the inside out, including N layers, i.e., 1...K...N, where N is greater than or equal to 2; Each layer of the conductor contains several turns, and each turn of the conductor is wound along the first long side, the first short side, the second long side, and the second short side of the coil body in sequence during the winding process; Its features are, In the first long side and the second long side, the wire of the K+1th layer is embedded in the gap formed by the adjacent wires of the Kth layer; In the first short side and the second short side, at least one of the short sides has its K+1 layer wires intersecting with the K layer wires in an X-shape, where 1≤K≤N-1.

13. The coil assembly as claimed in claim 12, characterized in that, In the X-shaped interleaving, the number of interleaved and bridging wires between the (K+1)th layer wire and the Kth layer wire is 2.

14. The coil assembly as claimed in claim 12, characterized in that, A cavity is formed inside the coil body. The cavity includes a long side and a short side. The length of the long side is greater than or equal to twice the length of the short side.

15. The coil assembly as claimed in claim 12, characterized in that, A cavity is formed inside the coil body. The cavity includes a long side and a short side. The length of the short side is greater than or equal to twice the diameter of the conductor.

16. The coil assembly as claimed in claim 15, characterized in that, The length of the short side of the cavity is 3-15 times the diameter of the wire.

17. The coil assembly as claimed in claim 12, characterized in that, The coil body has a cavity inside, which includes a long side and a short side. The length of the short side is greater than or equal to 1 mm and less than or equal to 5 mm. The diameter of the wire is greater than or equal to 0.1 mm and less than or equal to 1.0 mm.

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