A core winding method and winding equipment

Abstract

This invention discloses a method and equipment for winding an iron core, belonging to the field of iron core manufacturing. The method and equipment include a base, a rotating shaft for winding silicon steel sheets, and an ejection cylinder for ejecting the iron core from the outer side of the rotating shaft. Both the rotating shaft and the ejection cylinder are connected to the base and driven by it. The ejection cylinder is sleeved around the outer circumference of the rotating shaft and slidably connected to it. It also includes a magnetic attraction assembly and an inner support component. Multiple circumferentially distributed support rods are fixedly arranged at the end of the rotating shaft away from the base, with a support gap between adjacent support rods. The magnetic attraction assembly includes multiple magnetic blocks. The magnetic blocks are arc-shaped, and their shape matches the corresponding support gap for embedding within the gap. This allows the silicon steel sheets to be expanded internally, ensuring each layer of silicon steel sheets adheres tightly, freeing up equipment space. Simultaneously, it provides an external magnetic field during winding to promote magnetostriction of the silicon steel sheets, winding them into an iron core in an elongated state, thus preventing vibration during use.

Description

Technical Field

[0001] The invention belongs to the field of iron core manufacturing, and more specifically, relates to an iron core winding method and a winding device. Background Art

[0002] The common toroidal cores of mutual inductors and transformers are all made of silicon steel sheets wound by winding machines. The general winding machine, such as the fully automatic toroidal core winding machine model RC100-40 manufactured by Dongguan Morinaga Machinery Co., Ltd., has the following operation process: 1. The lead of the silicon steel sheet is pressed tightly through the abutment rod externally arranged on the rotating shaft; 2. The rotating shaft rotates so that the silicon steel sheet is attached to the surface of the rotating shaft to form a ring; 3. After the silicon steel sheet rotates one circle on the surface of the rotating shaft, the welding head externally arranged on the rotating shaft welds a circle of silicon steel sheets to fix it; 4. The rotating shaft continues to rotate, and the abutment rod changes the extended length in real time, so that the silicon steel sheets are stacked together in a spiral; 5. After the silicon steel sheet is wound for many circles, the welding head welds the outermost silicon steel sheet to fix it into a toroidal core. The core made by this method has an inner diameter equal to the outer diameter of the rotating shaft, and each layer of silicon steel sheets is tightly abutted, so its outer diameter is also unified and becomes a standard part.

[0003] The defect of the above-mentioned winding machine is that at least one abutment rod needs to be arranged outside the rotating shaft, and the abutment rod also needs to change the extension distance in real time to control the clamping force on the silicon steel sheet to avoid excessive magnetic gap and make each layer of silicon steel sheet close together; therefore, the abutment rod also needs hydraulic drive components and control components to match the operation. On the one hand, the space layout outside the rotating shaft is too compact, the equipment cost is relatively high, and the cost of maintaining the abutment rod and corresponding components is also relatively high, so the scope of applicable enterprises is not wide.

[0004] In addition, when the iron core is in use, the coil wound around the iron core is energized, so the iron core is in an external magnetic field, and the silicon steel sheet in the external magnetic field will produce magnetostriction, that is, the length becomes longer or shorter, and the thickness becomes thicker or thinner; when the silicon steel sheet is not in the electromagnetic field, the direction of the magnetic chips of the silicon steel sheet is distributed in a disorderly manner, and when the silicon steel sheet is in an external electromagnetic field, the direction of the magnetic chips of the silicon steel sheet is consistent with the direction of the magnetic field, and the shape of the silicon steel sheet changes from a macroscopic perspective; when the shape of the silicon steel sheet changes, there is a gap between the iron core, and the iron core will vibrate and generate noise when operating; therefore, the defect of the above-mentioned winding machine is that when the iron core is prepared, the silicon steel sheet is not in an elongated state under the action of the magnetic field, so that when the iron core is in use, the silicon steel sheet may continue to become thinner and elongated, resulting in gaps between the silicon steel sheets of the iron core and noise. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide an iron core winding method and a winding device, which can achieve the expansion inside the silicon steel sheet so that each layer of silicon steel sheet is close to each other, thereby releasing the space occupied by the equipment. At the same time, an external magnetic field is provided during winding to promote the silicon steel sheet to produce a magnetostrictive effect, and the iron core is wound in an extended state to avoid vibration of the iron core during use.

[0006] The object of the present invention is to disclose an iron core winding method, comprising a base, a rotating shaft for winding silicon steel sheets, and an exit cylinder for pushing out the iron core outside the rotating shaft; the rotating shaft and the exit cylinder are both connected to the base to be driven by the base; the exit cylinder is sleeved on the outer periphery of the rotating shaft and is slidably connected to the rotating shaft;

[0007] It also includes magnetic suction components and internal support parts;

[0008] A plurality of racks evenly distributed in a circumference are fixedly arranged at one end of the rotating shaft away from the base, and a racking gap is formed between adjacent racks;

[0009] The magnetic attraction assembly includes a plurality of magnetic blocks; the magnetic blocks are arc-shaped, and the shape of the magnetic blocks matches the corresponding mounting gap so as to be embedded and placed in the mounting gap; the head and tail ends of the magnetic blocks are magnetic poles; the adjacent ends of two adjacent magnetic blocks are magnetic poles with opposite magnetic properties; when winding, the outer arc surface of the magnetic block is connected to the outer side surface of the frame rod to form a circular surface, and the circular surface is in contact with the inner surface of the iron core;

[0010] The outer peripheral surface of the inner support member includes an arc surface so that the inner support member can be slidably connected to the magnetic attraction component; the outer diameter of the inner support member is at least larger than the inner diameter of the arc surrounded by multiple magnetic blocks during winding, so that the inner support member can directly or indirectly drive the inner diameter of the iron core to increase and tighten.

[0011] As a further improvement of the present invention, during winding, the inner end lead of the iron core maintains magnetic connection with the outer surface of any magnetic block.

[0012] As a further improvement of the present invention, the frame rods are made of non-magnetic materials; each magnetic block is an independent magnetic part; the angle between the magnetic field lines on the outside of each magnetic block and the winding direction of the silicon steel sheet is less than a preset threshold, so that the length of the silicon steel sheet when wound is greater than the length when it is non-magnetic.

[0013] As a further improvement of the present invention, the outer diameter of the inner support member is larger than the inner diameter of the arc formed by the multiple magnetic blocks during winding; in the tensioned state, the inner support member is embedded in the arc formed by the multiple magnetic blocks, the inner support member drives the magnetic blocks to move outward, the magnetic blocks drive the iron core to be tensioned, and the layers of silicon steel sheets are tightened against each other.

[0014] As a further improvement of the present invention, the inner support member is a columnar inner support column; a frame rod groove is opened on the outer diameter of the inner support column, and the number and shape of the frame rod groove are matched with the frame rod; the outer diameter of the inner support column is greater than or equal to the inner diameter of the arc formed by multiple frame rods; the depth of the frame rod groove is greater than the width of the welding head, so that the welding head can extend into the iron core through the frame rod groove for welding.

[0015] As a further improvement of the present invention, the head of the inner support column is conical; the inner side of the magnetic block away from the base is a conical surface matching the head of the inner support column.

[0016] As a further improvement of the present invention, the outer diameter of the inner support is larger than the inner diameter of the iron core during winding; in the tensioned state, the inner support is embedded between the iron core and the magnetic attraction component, and the inner support drives the iron core to move outward so that each layer of silicon steel sheets is close to each other, and the iron core is tensioned.

[0017] As a further improvement of the present invention, the inner support member is a cylindrical inner support tube; the inner support tube includes a tube body and a support frame; the support frame is fixedly connected to the inner wall of the tube body; the inner diameter of the tube body is larger than the inner diameter of the arc formed by multiple magnetic blocks during winding, and the inner side of the tube body close to the iron core is a conical surface, and the diameter of the small end of the conical surface is equal to the outer diameter of the arc formed by multiple magnetic blocks during winding.

[0018] As a further improvement of the present invention, the inner support tube is at least made of a water-soluble solid material; in the tensioned state, the inner support tube is in a dry environment to support the inner support tube.

[0019] Another object of the present invention is to disclose an iron core winding device, based on an iron core winding device, comprising the following steps:

[0020] S1. The magnetic block is embedded in the gap of the shaft, and the outer arc surface of the magnetic block is connected to the outer side surface of the frame rod to form a circular surface;

[0021] S2. The lead of the silicon steel sheet is fixed on the circular surface, the shaft rotates to achieve winding, and the magnetic block attracts the silicon steel sheet to maintain the curled shape;

[0022] S3. The silicon steel sheet is wound and the outermost end of the silicon steel sheet is fixed;

[0023] S4. The inner support is embedded in the inner side of the core to directly or indirectly support the core;

[0024] S5. The innermost lead of the silicon steel sheet is fixed to become the rough iron core.

[0025] As a further improvement of the present invention, the outermost ends of the silicon steel sheets are fixed by clamping.

[0026] As a further improvement of the present invention, the outermost ends of the silicon steel sheets are fixed by welding.

[0027] As a further improvement of the present invention, the innermost lead of the silicon steel sheet is fixed by welding.

[0028] As a further improvement of the present invention, the innermost lead of the silicon steel sheet is fixed by placing the iron core 4 in glue.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] The present invention arranges a magnetic attraction component in the iron core so that the iron core can be kept in a curled state for winding without an external driving force, thereby freeing up the equipment space outside the rotating shaft; after the winding is completed, an inner support column or an inner support cylinder is inserted into the inner side of the iron core so that the iron core is tensioned, and each layer of the silicon steel strip is tightly attached to each other, thereby avoiding the generation of magnetic gaps;

[0031] Since the total length of the silicon steel strip and the number of silicon steel sheet layers of the iron core are set, the inner diameter of the iron core can be predicted in order to make the silicon steel sheets close to each other. The present invention stabilizes the inner diameter of the iron core within a set range by inserting an inner support column or inner support cylinder as a rigid part to ensure that the iron core is tensioned without gaps. The method is simple and effective, and will not cause the iron core to be over-tensioned and broken, nor will it cause the iron core to be insufficiently tensioned and have gaps.

[0032] The presence of the magnet creates an external magnetic field. Due to the arc shape of the magnet, the direction of some magnetic flux lines is close to the winding direction of the silicon steel sheet, so that the silicon steel sheet is stretched to a certain length due to magnetostriction when winding, avoiding the magnetostriction phenomenon when the iron core is used, resulting in the thinning of the iron core, the generation of gaps between the layers, and the occurrence of working vibration;

[0033] In particular, the present invention arranges the inner support tube to be made of a water-soluble solid material. After the core winding and tensioning process is completed, the core and the inner support tube are simultaneously put into glue to fix the core. When the glue solidifies, it is put into water to dissolve the inner support tube. This arrangement allows the core to be fixed in a tensioned state, thereby avoiding the formation of gaps between layers of silicon steel sheets. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 This is a schematic diagram of the installation method of the magnetic attraction component of the specific embodiment 1 of the present invention;

[0035] Figure 2 This is a schematic diagram of the structure of the rotating shaft after the magnetic attraction component of the specific embodiment 1 of the present invention is installed;

[0036] Figure 3 It is a schematic diagram of the three-dimensional structure of the magnetic attraction component according to the first specific embodiment of the present invention;

[0037] Figure 4 It is a schematic diagram of the three-dimensional structure of the wound core of the specific embodiment 1 of the present invention;

[0038] Figure 5 This is a schematic diagram of the side structure of the rotating shaft after the magnetic attraction component of the specific embodiment 1 of the present invention is installed;

[0039] Figure 6 It is a schematic diagram of the matching mode between the support column and the magnetic attraction component of the specific embodiment 1 of the present invention;

[0040] Figure 7 It is a schematic diagram of the three-dimensional structure of the support column of the specific embodiment 1 of the present invention;

[0041] Figure 8 It is a structural schematic diagram of the iron core of the first specific embodiment of the present invention when it is withdrawn after winding is completed;

[0042] Fig. 9 Another structural schematic diagram of the iron core of the first specific embodiment of the present invention when it is withdrawn after winding is completed;

[0043] Fig.10 It is a schematic diagram of the matching mode between the support tube and the magnetic attraction component of the specific embodiment 2 of the present invention;

[0044] Fig.11 It is a structural schematic diagram of the iron core of the second specific embodiment of the present invention when it is withdrawn after winding is completed;

[0045] Fig.12 It is a schematic diagram of the three-dimensional structure of the inner support tube according to the second specific embodiment of the present invention.

[0046] Description of the numbers in the figure:

[0047] The rotating shaft 1, the magnetic attraction component 2, the withdrawal cylinder 3, the iron core 4, the inner support member 5, the inner support column 51, and the inner support cylinder 52. DETAILED DESCRIPTION

[0048] Specific embodiment 1: Please refer to Figure 1-9 A core winding device includes a base, a rotating shaft 1 for winding silicon steel sheets, and an exit cylinder 3 for pushing out an iron core 4 outside the rotating shaft 1; the rotating shaft 1 and the exit cylinder 3 are both connected to the base to be driven by the base; the exit cylinder 3 is sleeved on the outer periphery of the rotating shaft 1 and is slidably connected to the rotating shaft 1; the operating modes of the base, the rotating shaft 1, and the exit cylinder 3 are consistent with those of the existing fully automatic core winding machines, such as the fully automatic ring core winding machine model RC100-40 manufactured by Dongguan Morinaga Machinery Co., Ltd.; therefore, this part of the content is not repeated here.

[0049] Different from the prior art, a plurality of evenly distributed circular racks are fixedly provided at one end of the rotating shaft 1 away from the base, and there are rack gaps between adjacent racks; the racks are all made of non-magnetic material.

[0050] The winding device also includes a magnetic attraction component 2 and an inner support member 5.

[0051] The magnetic attraction component 2 includes a plurality of magnetic blocks, specifically four magnetic blocks in this embodiment; the plurality of magnetic blocks are the same component, the magnetic blocks are arc-shaped, and the shape of the magnetic blocks matches the corresponding mounting gap so as to be embedded and placed in the mounting gap; the head and tail ends of the magnetic blocks are magnetic poles; the proximal ends of two adjacent magnetic blocks are magnetic poles with opposite magnetic properties; when placed between the rack rods, the adjacent magnetic poles of the two adjacent magnetic blocks attract each other across the rack rods, which also ensures the stable placement of the magnetic blocks; when winding, the outer arc surface of the magnetic block is connected to the outer side surface of the rack rod to form a circular surface, which is the winding surface, and the circular surface is in contact with the inner surface of the iron core 4; when winding, the inner end lead of the iron core 4 A magnetic connection is maintained with the outer surface of any magnetic block so that one end of the silicon steel sheet is fixed to ensure that it can be curled. Due to the presence of the magnetic block, the silicon steel sheet can be automatically attracted by the magnetic block and bend to achieve winding; since the frame rods are made of non-magnetic conductive materials, each magnetic block is an independent magnetic part, and the angle between the magnetic field lines on the outside of each magnetic block and the winding direction of the silicon steel sheet is less than a preset threshold. Since the magnetic field lines are arc-shaped but not in a standard circle, the magnetic field lines must have an angle with the winding direction of the silicon steel sheet; the presence of the magnetic block causes magnetostriction in the silicon steel sheet when it is wound, making its length greater than its length when there is no magnetism.

[0052] The end of the magnetic block close to the base is the head, and the end away from the base is the tail; the tail of the magnetic block is chamfered inside and outside; the outer diameter of the magnetic block is consistent with the outer diameter of the root of the shaft 1, so that the exit tube 3 can push out the iron core 4 wound on the outside of the shaft 1 after axial movement.

[0053] The inner support member 5 is a columnar inner support column 51; the outer circumferential surface of the inner support column 51 is an arc surface, and the inner support column 51 can be extended into the hole surrounded by the inner arc surface of the magnetic block and is slidably connected with the hole; the head of the inner support column 51 is conical; the outer diameter of the inner support column 51 is provided with a rack rod groove, and the number and shape of the rack rod grooves are matched with the rack rods; the outer diameter of the inner support column 51 is larger than the inner diameter of the arc surrounded by multiple rack rods; the depth of the rack rod groove is larger than the width of the welding head, so that the welding head can be extended into the iron core 4 through the rack rod groove for welding.

[0054] When in use, since the outer diameter of the inner support member 5 is larger than the inner diameter of the arc formed by multiple magnetic blocks during winding, in the tensioned state, the inner support member 5 drives the magnetic blocks to move outward, and the magnetic blocks drive the iron core 4 to be tensioned, and each layer of silicon steel sheets is tightened against each other; the frame rod is embedded in the corresponding frame rod groove.

[0055] Based on the iron core winding device provided in this embodiment, the iron core winding method includes the following steps:

[0056] S1. The magnetic block is embedded in the gap of the shaft 1, and the outer arc surface of the magnetic block is connected to the outer side surface of the frame rod to form a circular surface;

[0057] S2. The lead of the silicon steel sheet is transferred to fit the circular surface, at which time the lead is fitted and connected to the surface of any magnetic block and fixed on the circular surface by magnetic attraction. The shaft 1 rotates to achieve winding, and the magnetic block attracts the silicon steel sheet to maintain a curled shape;

[0058] S3. After the silicon steel sheet is wound, the outermost end of the silicon steel sheet is fixed by clamping or welding;

[0059] S4. The inner support column 51 is embedded in the inner side of the core 4, the inner support column 51 opens the magnetic block, and the magnetic block then opens the core 4. At this time, there is no gap between the layers of silicon steel sheets in the core 4, and the tension is maintained;

[0060] S5. Move the exit tube 3 and remove the inner support column 51. The iron core 4, the magnetic block and the inner support column 51 are removed together. The welding head extends into the frame rod groove to weld the innermost layer of the silicon steel sheet to form a rough iron core 4.

[0061] After the rough product is made, the support column 51 and the magnetic block are removed, and the iron core 4 is placed in the glue, and the finished product is obtained after the glue is cured.

[0062] Specific embodiment 2: Different from specific embodiment 1, please refer to Figure 10-12 An iron core winding device, wherein the inner support member 5 is a cylindrical inner support tube 52; the inner support tube 52 includes a tube body and a support frame; the support frame is fixedly connected to the inner wall of the tube body; the inner diameter of the tube body is larger than the inner diameter of the arc formed by multiple magnetic blocks during winding, and the outer diameter of the inner support member 5 is larger than the inner diameter of the iron core 4 during winding; the inner side of the tube body close to the iron core 4 is a conical surface, and the small end diameter of the conical surface is equal to the outer diameter of the arc formed by multiple magnetic blocks during winding.

[0063] In the tensioned state, the inner support tube 52 is inserted between the iron core 4 and the magnetic attraction assembly 2, and the inner support tube 52 drives the iron core 4 to move outward so that each layer of silicon steel sheets is closely attached to each other, and the iron core 4 is tensioned.

[0064] At least the body of the inner support tube 52 is made of a water-soluble solid material; in a tensioned state, the inner support tube 52 is in a dry environment to support the inner support tube 52 .

[0065] Based on the iron core winding device provided in this embodiment, the iron core winding method includes the following steps:

[0066] S1. The magnetic block is embedded in the gap of the shaft 1, and the outer arc surface of the magnetic block is connected to the outer side surface of the frame rod to form a circular surface;

[0067] S2. The lead of the silicon steel sheet is transferred to fit the circular surface, at which time the lead is fitted and connected to the surface of any magnetic block and fixed on the circular surface by magnetic attraction. The shaft 1 rotates to achieve winding, and the magnetic block attracts the silicon steel sheet to maintain a curled shape;

[0068] S3. After the silicon steel sheet is wound, the outermost end of the silicon steel sheet is fixed by clamping or welding;

[0069] S4. The end face of the head of the inner support tube 52 is abutted against the end face of the tail of the frame rod, and the tube 3 is moved out of the tube 3. The core 4 is pushed to the outer periphery of the inner support tube 52. At this time, the inner support tube 52 is embedded in the inner side of the core 4. The inner support tube 52 opens the core 4. At this time, there is no gap between the layers of silicon steel sheets of the core 4, and the tension is maintained;

[0070] S5. Take out the magnetic block, place the iron core 4 and the inner support tube 52 together in the glue, and after the glue solidifies, place the iron core 4 and the inner support tube 52 together in the water, and after the water-soluble solid material of the inner support tube 52 is dissolved, separate the iron core 4 from the inner support tube 52. The iron core 4 can be directly regarded as a finished product, or it can be regarded as a finished product after being welded on the innermost silicon steel sheet of the iron core 4.

[0071] Specific embodiment three: Different from specific embodiment one, the outer circumference of the inner support column 51 is a smooth, continuous, complete circular surface, that is, no rack rod groove is provided; the outer diameter of the inner support column 51 is equal to the inner diameter of the arc formed by multiple rack rods.

[0072] This arrangement ensures that the maximum outward movement distance of the magnetic block is fixed, and in the tensioned state, the inner arc surface of the magnetic block is flush with the inner arc surface of the rack rod.

Claims

1. An iron core winding device, comprising a base, a rotating shaft (1) for winding silicon steel sheets, and an ejection cylinder (3) for ejecting an iron core (4) outside the rotating shaft (1); the rotating shaft (1) and the ejection cylinder (3) are both connected to the base to be driven by the base; the ejection cylinder (3) is sleeved on the outer periphery of the rotating shaft (1) and is slidably connected to the rotating shaft (1); characterized in that: It also includes a magnetic attraction component (2) and an inner support component (5); A plurality of frame rods evenly distributed in a circumferential shape are fixedly arranged at one end of the rotating shaft (1) away from the base, and there are frame gaps between adjacent frame rods; The magnetic attraction assembly (2) comprises a plurality of magnetic blocks; the magnetic blocks are arc-shaped, and the shapes of the magnetic blocks match the corresponding mounting gaps so as to be embedded and placed in the mounting gaps; the head and tail ends of the magnetic blocks are magnetic poles; the adjacent ends of two adjacent magnetic blocks are magnetic poles with opposite magnetic properties; when winding, the outer arc surface of the magnetic block is connected to the outer side surface of the frame rod to form a circular surface, and the circular surface is in contact with the inner surface of the iron core (4); The outer peripheral surface of the inner support member (5) comprises an arc surface, so that the inner support member (5) can be slidably connected to the magnetic attraction component (2); the outer diameter of the inner support member (5) is larger than the inner diameter of the arc formed by the plurality of magnetic blocks when winding; in a tensioned state, the inner support member (5) is embedded in the arc formed by the plurality of magnetic blocks, the inner support member (5) drives the magnetic blocks to move outward, the magnetic blocks drive the iron core (4) to be tensioned, and the layers of silicon steel sheets are closely attached to each other.

2. The core winding device according to claim 1, characterized in that: During winding, the inner end lead of the iron core (4) maintains magnetic connection with the outer surface of any magnetic block.

3. The core winding device according to claim 1, characterized in that: The frame rods are all made of non-magnetic materials; each magnetic block is an independent magnetic part; the angle between the magnetic field lines on the outside of each magnetic block and the winding direction of the silicon steel sheet is less than a preset threshold, so that the length of the silicon steel sheet when wound is greater than the length when it is non-magnetic.

4. The core winding device according to claim 1, characterized in that: The inner support member (5) is a columnar inner support column (51); the outer diameter of the inner support column (51) is provided with a rack rod groove, the number and shape of the rack rod grooves match the rack rods; the outer diameter of the inner support column (51) is greater than or equal to the inner diameter of a circular arc formed by a plurality of rack rods; the depth of the rack rod groove is greater than the width of the welding head, so that the welding head can extend through the rack rod groove into the iron core (4) for welding.

5. The core winding device according to claim 4, characterized in that: The head of the inner support column (51) is conical; the inner side of the magnetic block away from the base is a conical surface matching the head of the inner support column (51).

6. A core winding method, characterized in that: A core winding device according to any one of claims 1 to 5, comprising the following steps: S1. The magnetic block is embedded in the gap of the rotating shaft (1), and the outer arc surface of the magnetic block is connected to the outer side surface of the frame rod to form a circular surface; S2. The lead of the silicon steel sheet is fixed on the circular surface, the shaft (1) rotates to achieve winding, and the magnetic block attracts the silicon steel sheet to maintain the curled shape; S3. The silicon steel sheet is wound and the outermost end of the silicon steel sheet is fixed; S4. The inner support member (5) is embedded in the inner side of the core (4), directly or indirectly supporting the core (4); S5. The innermost lead of the silicon steel sheet is fixed to form the rough product of the iron core (4).

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