An automatic winding machine, winding method and stator

Abstract

The present application relates to automatic winding technical field, especially in kind of automatic winding machine, winding method and stator, it includes; base, winding mechanism and hooking mechanism, winding mechanism activity sets up on base, winding mechanism contains placement tool and winding disc, the outer diameter of winding disc is greater than the outer diameter of placement tool, hooking mechanism activity sets up on base, and is located in winding mechanism one side, hooking mechanism can extend into winding mechanism;By this, through increasing the diameter of winding disc, the distance of winding column to stator core in placement tool is extended, the number of winding turns of lead-out wire on winding disc is reduced, the lead-out wire on winding disc tends to be regular, so that the technical effect of facilitating subsequent operation is achieved;At the same time, cooperate with hooking mechanism, can independently select same side winding method or different side winding method, not only reduces the production cost, and improves production efficiency.

Description

Technical Field

[0001] This invention relates to the field of automatic winding technology, and in particular to an automatic winding machine, winding method and stator. Background Technology

[0002] In the motor industry, stator winding production mostly uses automatic winding machines to achieve the purpose of saving production costs and improving production efficiency. It usually consists of a winding nozzle and a placement fixture. The winding nozzle clamps the wire and winds the wire evenly on the stator in the placement fixture.

[0003] Currently, existing automatic winding machines typically mount the winding reel on top of the product placement fixture. The reel is equipped with winding posts, and the length of the lead wire is controlled by increasing the number of turns the lead wire makes on the reel. However, for products requiring electromagnetic technology processes with 2, 4, or more parallel windings, the lead wires are usually 6, 12, 24, or more. Since the process requires each lead wire to be longer than or equal to the circumference of the core, if the bridge wire and lead wires are wound on the same side of the stator core during winding, the repeated winding of the lead wires can easily result in a messy, "spider web" pattern, which is detrimental to subsequent production.

[0004] To ensure the smooth operation of subsequent processes, most existing automatic winding machines use a winding method that winds the bridge wire and the lead wire on opposite sides of the stator core. However, this method has high requirements for the wire material, which leads to a decrease in yield and increases production costs.

[0005] It should be noted that the information disclosed in this background section is intended only to enhance the understanding of the overall background of the present invention, and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0006] To address the aforementioned technical problems of inconvenient production and high production costs, this invention provides an automatic winding machine. The winding machine includes a base, a winding mechanism, and a hooking mechanism. The winding mechanism is movably mounted on the base and includes a placement fixture and a winding reel. The placement fixture is movably connected to the base and has a hollowed-out portion. The winding reel is mounted on the placement fixture, and its outer diameter is larger than the outer diameter of the placement fixture. The winding reel has multiple spaced-apart winding posts.

[0007] The hooking mechanism is mounted on the machine base and is movably connected to the machine base. The hooking mechanism is located on the side of the winding mechanism and can extend into the placement fixture through the hollow part.

[0008] Furthermore, the placement fixture is provided with two hooks, which are distributed at 90° to the bottom of the placement fixture.

[0009] Furthermore, the cutout is greater than 180°.

[0010] Furthermore, the outer diameter of the winding reel is 1.5 to 2.5 times the outer diameter of the placement fixture.

[0011] Furthermore, the number of winding posts is 12, and the 12 winding posts are evenly distributed in a ring on the winding reel and adjacent to the outer edge of the winding reel, with the included angle between two adjacent winding posts being 30°.

[0012] Furthermore, the winding spool is provided with a plurality of observation holes, which are evenly and spaced apart on the winding spool.

[0013] Furthermore, the hooking mechanism includes a drive unit, a first cylinder, a second cylinder, and a gripper. The drive unit is movably connected to the machine base. The first cylinder is disposed on the drive unit, and the second cylinder is disposed on the first cylinder. The gripper is throttle-connected to the second cylinder, and the gripper can extend into the placement fixture.

[0014] Furthermore, the hooking mechanism also includes a hooking wheel, which is disposed on the gripper.

[0015] Furthermore, the automatic winding machine also includes a winding nozzle, which is movably connected to the machine base and can extend into the placement fixture.

[0016] The present invention also provides a winding method, which uses the above-mentioned automatic winding machine for winding, and the winding method includes same-side winding or opposite-side winding.

[0017] The present invention also provides a stator, which is wound using the above-described winding method.

[0018] Based on the above, the automatic winding machine, winding method, and stator provided by the present invention, compared with the prior art, reduce the number of turns of the lead wire on the winding reel by increasing the diameter of the winding reel and extending the distance from the winding post to the stator core in the placement fixture, making the lead wire on the winding reel more regular; thus achieving the technical effect of facilitating subsequent processing operations. At the same time, in conjunction with the hooking mechanism, the same-side winding method or opposite-side winding method can be selected independently, which not only reduces production costs but also improves production efficiency. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Unless otherwise specified, the positional relationships in the drawings described below are based on the direction in which the components are drawn in the figures.

[0020] Figure 1 This is a schematic diagram of the structure of an automatic winding machine provided in an embodiment of the present invention;

[0021] Figure 2 This is a schematic diagram of the winding mechanism and hooking mechanism provided in an embodiment of the present invention;

[0022] Figure 3 This is a schematic diagram of the structure of the hollowed-out portion provided in an embodiment of the present invention;

[0023] Figure 4 for Figure 3 Schematic diagram of the cross-sectional structure at point AA;

[0024] Figure 5 This is a top view of the winding reel.

[0025] Figure label:

[0026] 10-Base; 20-Winding mechanism; 30-Hook mechanism

[0027] 40-Openwork section 50-Crochet hook 60-Wrapping post

[0028] 70 - Observation hole; 80 - Winding nozzle; 90 - Wire guard plate

[0029] 21-Placement fixture 22-Winding reel 31-Drive unit

[0030] 32-First cylinder 33-Second cylinder 34-Hand clamp

[0031] 35-Hookline reel Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] In the description of this invention, it should be noted that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance, or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more. Additionally, the term "comprising" and any variations thereof mean "at least comprising."

[0034] Please see Figure 1 and Figure 2 , Figure 1 This is a schematic diagram of the structure of an automatic winding machine provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the winding mechanism and the hooking mechanism provided in an embodiment of the present invention.

[0035] To address the aforementioned technical problems of inconvenient production and high production costs, or to achieve at least one or more of the advantages mentioned above, an embodiment of the present invention provides an automatic winding machine. As shown in the figure, the automatic winding machine includes a base 10, a winding mechanism 20, and a hooking mechanism 30.

[0036] The winding mechanism 20 is movably mounted on the base 10. In a specific implementation, the winding mechanism 20 includes a placement fixture 21 and a winding reel 22. The placement fixture 21 is movably connected to the base 10 and can rotate relative to the base 10 to cooperate with the winding operation.

[0037] Please combine Figure 2 See Figure 3 and Figure 4 As shown in the figure, the placement fixture 21 has a cutout portion 40. The hooking mechanism 30 can extend into the placement fixture 21 through the cutout portion 40, thereby hooking the lead wire out of the placement fixture 21 and controlling the length of the lead wire. Specifically, the cutout angle of the cutout portion 40 is greater than 180°, ensuring that even if the placement fixture 21 rotates relative to the machine base 10 during the winding process, the hooking mechanism 30 can still extend into the placement fixture 21 to clamp the lead wire, hook the lead wire out of the placement fixture 21, and control the length of the lead wire.

[0038] The placement fixture 21 is equipped with two hooks 50. The two hooks 50 are positioned at a 90° angle at the bottom of the placement fixture 21 to better assist in the winding process. It is understood that the number and angle of the hooks 50 can be varied according to the number of slots in the stator core and the requirements of the winding diagram. In this embodiment, taking a 6-slot stator core as an example, only two hooks 50 are needed to complete the auxiliary winding work during the winding process, and the lead-out wire span is exactly 90°.

[0039] In some preferred embodiments, the hook 50 is provided with a set screw groove (not shown in the figure). The hook 50 is engaged with the placement fixture 21 through the set screw groove, and can be secured to the placement fixture 21 by a bolt with a set screw, ensuring that the hook 50 is securely installed on the placement fixture 21.

[0040] Please combine Figure 2 See Figure 5 The winding reel 22 is mounted on the placement fixture 21. When the placement fixture 21 rotates relative to the machine base 10, it synchronously drives the winding reel 22 to rotate. The winding reel 22 is provided with multiple spaced winding posts 60 for winding the lead wire. The outer diameter of the winding reel 22 is larger than the outer diameter of the placement fixture 21, thus extending the distance from the winding posts 60 to the stator core in the placement fixture 21.

[0041] Specifically, the outer diameter of the winding reel 22 is 1.5 to 2.5 times the outer diameter of the placement fixture 21. During the winding process, because the distance between the winding post 60 and the stator core in the placement fixture 21 is extended, the lead wire only needs to be wound a short distance on the winding post 60 (e.g., one-third of a turn, half a turn, etc.). At this time, the length of the lead wire is equal to the circumference of the stator core or slightly longer, meeting the requirements of the leveling process. There is no need for full-turn winding, nor is it necessary to control the length of the lead wire by increasing the number of winding turns. This avoids the formation of a "spider web" shape from repeatedly wound lead wires, making the lead wire more regular and facilitating subsequent processes.

[0042] Understandably, in order to achieve compatibility with small-diameter stator cores and stator cores of the same diameter but different heights, equal-circle pads or equal-height pads (conventional components) can be added to the placement fixture 21 to achieve compatibility with small-diameter stator cores and stator cores of the same diameter but different heights. In this case, the winding length of the lead wire can be further reduced, and the most suitable lead wire length can also be obtained.

[0043] In some preferred embodiments, the number of winding posts 60 is 12. The 12 winding posts 60 are evenly distributed in a ring on the winding reel 22, and the included angle between two adjacent winding posts 60 is 30°, which facilitates the selection of the optimal winding post position for the lead wire and makes it easier to adjust.

[0044] Based on the above, all 12 winding posts 60 are located near the outer edge of the winding reel 22 (away from the edge of the tooling 21) to ensure that the length of the lead wire can be adjusted and controlled. The winding reel 22 with a small outer diameter is used to avoid the outer diameter of the winding reel 22 being too large and occupying equipment space.

[0045] In some preferred embodiments, because the outer diameter of the winding reel 22 is increased, the view of the operator may be obstructed during the production process. Therefore, multiple observation holes 70 are provided on the winding reel 22. The multiple observation holes 70 are evenly and spaced apart on the winding reel 22. During the winding process, the automatic winding status can be viewed in real time through the observation holes 70, which is convenient for debugging and monitoring.

[0046] The hooking mechanism 30 is mounted on the base 10. The hooking mechanism 30 is movably connected to the base 10 and is located on the side of the winding mechanism 20. The hooking mechanism 30 can move relative to the base 10 toward the winding mechanism 20.

[0047] In a specific implementation, the hooking mechanism 30 includes a drive unit 31, a first cylinder 32, a second cylinder 33, and a gripper 34. The drive unit 31 is movably connected to the base 10 and can move relative to the base 10. The first cylinder 32 is mounted on the drive unit 31, and the drive unit 31 can drive the first cylinder 32 to move. The second cylinder 33 is mounted on the first cylinder 32, and the first cylinder 32 can control the movement of the second cylinder 33 in the vertical direction. The gripper 34 is drivenly connected to the second cylinder 33, and the second cylinder 33 can control the opening and closing of the gripper 34. Preferably, the hooking mechanism 30 further includes a hooking wheel 35, which is mounted on the gripper 34.

[0048] During the winding process, when the lead wire needs to be hooked out of the placement fixture 21, the drive unit 31 moves, causing the first cylinder 32, the second cylinder 33, and the gripper 35 to move synchronously towards the placement fixture 21. This allows the gripper 34 to extend into the placement fixture 21 through the cutout 40. The first cylinder 32 controls the second cylinder 33 to move vertically, ensuring the gripper 34 is in the appropriate position. At this point, the second cylinder 33 controls the gripper 34 to open, and after the hook wheel 35 clamps the lead wire, the second cylinder 33 controls the gripper 34 to close. The drive unit 31 then moves in the opposite direction, causing the lead wire to be hooked out of the placement fixture 21 by the hook wheel 35. By setting and controlling the movement distance of the drive unit 31, the length of the lead wire can be controlled.

[0049] Based on the above, the automatic winding machine also includes a winding nozzle 80. The winding nozzle 80 is movably connected to the machine base 10 and can extend into the placement fixture 21 to wind the wire. In the specific winding process, the winding nozzle 80 first winds the wire onto the winding post 60, realizing the external winding of the lead wire and controlling and adjusting the length of the lead wire. Subsequently, the winding nozzle 80 moves and extends into the placement fixture 21 to wind the stator core. During this process, the hook 50 can stably hook the wire to assist in the winding work, while the hook wheel 35 can extend into the placement fixture 21 to hook out the lead wire and control its length.

[0050] In some preferred embodiments, the automatic winding machine also includes a wire guard plate 90, which is fixed on the machine base 10. The wire guard plate 90 is located on one side of the winding mechanism 20 and parallel to the hooking mechanism 30. The side of the wire guard plate 90 facing the winding mechanism 20 is a smooth surface, which is used to protect the hooked lead wire and prevent scratches during the rotation of the placement fixture 21, which would cause damage to the wire coating.

[0051] In some preferred embodiments, the present invention also provides a winding method, which uses the above-mentioned automatic winding machine for winding, and the winding method includes same-side winding or opposite-side winding.

[0052] The same-side wrapping method includes at least the following steps:

[0053] S1: The winding nozzle 80 winds the wire around the winding post 60, realizing the functions of winding the lead wire externally and controlling and adjusting the length of the lead wire.

[0054] S2: The winding nozzle 80 clamps the wire and extends it into the placement fixture 21, and winds the first coil of the stator core in the placement fixture 21.

[0055] S3: After the first coil is wound, the winding nozzle rises 80 degrees and passes through the bridge wire on the upper wire frame of the stator core, and then the second coil is wound.

[0056] S4: After the second coil is wound, the winding nozzle 80 rises and the lead wire is wound around the winding post 60 again, and the length of the lead wire is controlled and adjusted.

[0057] Repeat steps S3 and S4 above until all coils are wound.

[0058] The opposite-side winding method includes at least the following steps:

[0059] S1: The winding nozzle 80 extends into the placement fixture 21 and winds the first coil of the stator core in the placement fixture 21.

[0060] S2: After the first coil is wound, the winding nozzle 80 rises, the fixture 21 rotates, and the bridge wire passes over the upper wire frame of the stator core, while the second coil is wound at the same time.

[0061] S3: After the first and second coils are wound, the winding nozzle 80 is lowered further to the hook 50. By rotating the placement fixture 21, the lead wire is hooked by the hook 50.

[0062] S4: The hook mechanism 30 moves, the hook wheel 35 hooks the lead line on the hook 50 and places it in the fixture 21, and adjusts and controls the length of the lead line.

[0063] S5: After the lead wire is hooked out, place fixture 21 and rotate it to start winding the third coil.

[0064] Repeat steps S2-S5 above until all coils are wound.

[0065] In some preferred embodiments, the present invention also provides a stator wound using the above-described winding method. Compared with the stator wound by a conventional automatic winding machine, the lead wires are more regular, which facilitates subsequent processes, results in a high yield, and allows for the selection of same-side winding or opposite-side winding methods according to production needs.

[0066] In summary, the automatic winding machine, winding method, and stator provided by this invention, compared with the prior art, reduce the number of turns of the lead wire on the winding reel by increasing the diameter of the winding reel and extending the distance from the winding post to the stator core in the placement fixture, making the lead wire on the winding reel more regular. This achieves the technical effect of facilitating subsequent processing operations. At the same time, with the hooking mechanism, it is possible to choose between same-side winding or opposite-side winding, which not only reduces production costs but also improves production efficiency.

[0067] Although this document frequently uses terms such as placement fixture, winding reel, winding post, and cutout section, the possibility of using other terms is not excluded. These terms are used merely for the convenience of describing and explaining the essence of the invention; interpreting them as any additional limitation would contradict the spirit of the invention.

[0068] Furthermore, those skilled in the art should understand that although many problems exist in the prior art, each embodiment or technical solution of the present invention can be improved in only one or a few aspects, without necessarily solving all the technical problems listed in the prior art or the background art simultaneously. Those skilled in the art should understand that any content not mentioned in a claim should not be construed as a limitation on that claim.

[0069] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An automatic winding machine, characterized in that: include Base; A winding mechanism is movably mounted on a machine base. The winding mechanism includes a placement fixture and a winding reel. The placement fixture is movably connected to the machine base and has a cutout portion greater than 180°. The winding reel is mounted on the placement fixture, and its outer diameter is larger than that of the placement fixture. The winding reel has multiple spaced-apart winding posts and multiple observation holes. The outer diameter of the winding reel is 1.5 to 2.5 times the outer diameter of the placement fixture. A hooking mechanism is provided on the machine base and is movably connected to the machine base. The hooking mechanism is located on the side of the winding mechanism. The hooking mechanism can extend into the placement fixture through the hollow part to hook the lead wire out of the placement fixture and adjust and control the length of the lead wire. The automatic winding machine also includes a wire guard plate, which is fixed on the machine base. The wire guard plate is located on one side of the winding mechanism and parallel to the hooking mechanism. The side of the wire guard plate facing the winding mechanism is a smooth surface. The automatic winding mechanism also includes a circular pad or a height pad, which is located in the placement fixture.

2. The automatic winding machine according to claim 1, characterized in that: The placement fixture is equipped with two hooks, which are distributed at 90° angles at the bottom of the placement fixture.

3. The automatic winding machine according to claim 1, characterized in that: The number of winding posts is 12. The 12 winding posts are evenly distributed in a ring on the winding reel and are close to the outer edge of the winding reel. The included angle between two adjacent winding posts is 30°.

4. The automatic winding machine according to claim 1, characterized in that: The observation holes are evenly and spaced apart on the winding spool.

5. The automatic winding machine according to claim 1, characterized in that: The hooking mechanism includes a drive unit, a first cylinder, a second cylinder, and a gripper. The drive unit is movably connected to the machine base. The first cylinder is mounted on the drive unit, and the second cylinder is mounted on the first cylinder. The gripper is throttle-connected to the second cylinder and can extend into the placement fixture. The hooking mechanism also includes a hooking wheel, which is disposed on the clamp.

6. The automatic winding machine according to claim 1, characterized in that: The automatic winding machine also includes a winding nozzle, which is movably connected to the machine base and can extend into the placement fixture.

7. A winding method, characterized in that: The winding is performed using an automatic winding machine as described in claims 1-6, wherein the winding method includes same-side winding or opposite-side winding.

8. A stator, characterized in that: It is wound using the winding method described in claim 7.

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