Automatic winding machine for the internal coils of track blocks

Abstract

The present invention relates to an automatic winding machine for the internal coils of a track building block. The synchronous control system includes a second servo motor, a first slide, and a screw platform carrying a wire feed tension system, which receives input instructions from a processor to achieve matching of the coil diameter with the stroke of the straight enameled wire; further includes a servo and a shape selection lever arranged on the second slide, and the second slide is arranged vertically; the first slide is connected to the second slide via a connector and a tension wheel module, and the enameled wire to be wound is maintained on a vertical plane through the tension wheel module; the track motion system includes a first servo motor, and the first servo motor is connected to a horizontal iron rod that fixes the track of the coil to be wound; the processor obtains the servo motor encoder value of the track motion system, combines the number of servo motor lines, the reduction ratio, and the radius of the track of the coil to be wound, and obtains the number of movement circles of the track of the coil to be wound. The present invention can effectively improve the efficiency of batch winding and effectively improve the diversity and adaptability of products.

Description

Technical Field

[0001] The present invention relates to the technical field of mechanical winding and automatic control, in particular to an automatic winding machine for internal coils of track building blocks. Background Art

[0002] In traditional coil winding machines, a combination of gear sets can convert the rotation of the rocker into the rotation of the coil track to achieve manual winding. When the size of the coil track is determined, the traditional manual winding machine can use the gear set to drive the coil track to be wound. However, this design has the following problems and disadvantages:

[0003] 1. Traditional manual winding machines can perform basic winding movements, but the coil diameter needs to match the travel of the straight enameled wire. Sometimes it is difficult to make each turn of the coil close together, and the need to manually press the coil tightly greatly increases the user's difficulty in operation;

[0004] 2. Traditional coil winding machines require readjustment of the position of the limiting ring when winding different coil tracks or placing them in different positions. The position of the limiting ring that can achieve simple winding is unique, and this position needs to be adjusted during winding.

[0005] 3. When performing cross-winding operations on traditional coil winding machines, the enameled wire needs to be manually pulled to the corresponding position, which affects work efficiency;

[0006] The following problems and shortcomings exist for simple electric-controlled winding machines that use motors instead of rockers: 1. Since simple electric-controlled winding machines do not have manual auxiliary pressing, they cannot solve the problem of each turn of the coil not being close together due to the mismatch between the coil diameter and the enameled wire stroke, which greatly reduces the attraction of the building block track to the iron ball and affects the subsequent winding; 2. Simple electric-controlled winding machines cannot perform cross-winding operations. 3. Simple electric-controlled winding machines cannot switch between forward and reverse rotation as needed during operation. In the absence of a processor, the position of the limit ring still needs to be manually adjusted, and the need for fully automatic winding cannot be met. For this reason, we propose an automatic winding machine for the internal coils of the track building blocks. Summary of the Invention

[0007] In response to the above problems, the present invention provides an automatic winding machine for the internal coils of track building blocks, which can effectively improve the efficiency of batch winding, can wind different coil shapes, and effectively improve the diversity and adaptability of the product.

[0008] To this end, the present invention adopts the following technical solution: an automatic winding machine for the internal coil of a track building block, comprising a wire feed tension system and a track motion system, characterized in that it also includes a synchronous control system and a shape limiting system, the synchronous control system comprising a second servo motor, a first slide and a screw platform carrying the wire feed tension system, the synchronous control system accepts input instructions from a processor to achieve matching of the coil diameter with the straight enameled wire stroke; the shape limiting system comprises a servo and a shape selection lever arranged on the second slide, and the second slide is vertically arranged; the first slide is connected to the second slide through a connecting piece and a tension wheel module, and the enameled wire to be wound is maintained on a vertical plane through the tension wheel module; the track motion system comprises a first servo motor, and the first servo motor is connected to a horizontal iron rod that fixes the track of the coil to be wound;

[0009] The processor obtains the servo motor encoder value of the track motion system, and combines the servo motor line number, reduction ratio and the track radius of the coil to be wound to obtain the number of orbital motion circles of the coil to be wound. The calculation formula is as follows:

[0010]

[0011] Among them, N is the number of turns, L is the path length, P is the number of encoder pulses, R is the encoder resolution (the number of pulses output per turn), i is the reduction ratio (the ratio of input speed to output speed), and d is the diameter of the enameled wire.

[0012] Preferably, the servo receives a PWM signal value according to the required mold shape transmitted by the processor, and changes the angle of its own steering wheel to cooperate with the track motion system to wind different coil shapes.

[0013] Preferably, the steering gear is connected to the movable platform of the second slide, the shape selection rod is connected to the steering gear, the shape mold is mounted on the shape selection rod, and a pressure sensor is attached to the bottom of the shape mold.

[0014] Preferably, the first servo motor is arranged at the outermost side of the winding machine and is connected to the iron rod on which the track of the coil to be wound is placed via a set screw.

[0015] Preferably, the starting end of the iron rod is provided with a hole for placing a set screw, the middle end is a smooth round rod for placing the coil track to be wound, and the tail end is a threaded rod for tightening a nut on the coil track to be wound.

[0016] Preferably, the wire feeding tension system includes a tension wheel module, and the tension wheel module includes at least three tension wheels arranged side by side.

[0017] Preferably, the processor controls the rotation speed of the tension wheel through a PID algorithm to stabilize the tension between the enameled wire and the tension wheel to a set value.

[0018] Preferably, the first servo motor, the second servo motor, the first slide, the second slide and the tension wheel module simultaneously feed back various operating parameters to the processor and receive motion signals processed by the processor.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] 1. The dual servo motors automatically control the coil track and coils to be wound, greatly reducing the user's operating difficulty. The operator only needs to fix the coil track to the middle section of the iron rod and modify the processor program according to their own needs and the scale value of the corresponding parameter below, effectively improving the efficiency of batch winding.

[0021] 2. By matching the track motion system and the synchronous control system, the coil diameter is matched with the enameled wire stroke, and each turn of the coil is closely connected, which effectively improves the attraction of the building block track coil to the iron ball, effectively improves the aesthetics of the building block track coil, and reduces the difficulty of subsequent assembly.

[0022] 3. By selecting the appropriate shape-limiting mold, the track coil can be wound in various shapes, effectively improving the space utilization of the enameled wire. By adjusting the servo angle, the processor can switch between different shape-limiting molds to produce different coil shapes, effectively increasing product diversity and adaptability.

[0023] 4. The automatic winding machine for the internal coils of the aforementioned track blocks incorporates multiple feedback loops, significantly improving system stability and accuracy. Changing the processor program also allows for a leapfrog winding technique, difficult to achieve with existing technology, representing a significant technological breakthrough. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a structural schematic diagram of the core part of the automatic winding machine of the present invention.

[0025] Figure 2 This is a schematic diagram of the core overall structure of the present invention from another angle.

[0026] Figure 3 Schematic diagram of the first servo motor of the present invention.

[0027] Figure 4 Schematic diagram of the iron rod of the present invention.

[0028] Figure 5 Schematic diagram of the first slide of the present invention.

[0029] Figure 6 Schematic diagram of the tension wheel module of the present invention.

[0030] Figure 7 Schematic diagram of the second slide of the present invention.

[0031] Figure 8 Schematic diagram of the steering gear of the shape limiting system of the present invention.

[0032] In the figure: 1. first servo motor; 2. iron rod; 3. first slide; 4. second slide; 5. servo; 6. tension wheel module; 7. screw hole; 8. threaded rod. DETAILED DESCRIPTION

[0033] The present invention will be further described below with reference to specific embodiments.

[0034] like Figures 1-4 As shown, the present invention discloses an automatic winding machine for the internal coil of a track building block, comprising a wire feeding tension system, a track motion system, a synchronous control system and a shape limiting system.

[0035] The track motion system comprises a first servo motor 1 and a horizontally positioned iron rod 2. The rod 2 has a screw hole 7 at its leading end for a set screw. Its middle end is a smooth, round rod for the coil track. Its trailing end is a threaded rod 8, which is used to tighten the nut around the coil track. Both ends are tightened to secure the rod 2. The first servo motor is connected to its dedicated driver board, which provides feedback to the controller, including position, speed, and travel distance.

[0036] The synchronous control system includes a second servo motor, a first slide 3 and a screw platform that carries the wire feeding tension system. The synchronous control system receives input instructions from the processor to match the coil diameter with the straight enameled wire stroke. The second servo motor drives the movement of the first slide 3.

[0037] The processor obtains the servo motor encoder value of the track motion system, and combines the servo motor line number, reduction ratio and the track radius of the coil to be wound to obtain the number of orbital motion circles of the coil to be wound. The calculation formula is as follows:

[0038]

[0039] Among them, N is the number of turns, L is the path length, P is the number of encoder pulses, R is the encoder resolution (the number of pulses output per turn), i is the reduction ratio (the ratio of input speed to output speed), and d is the diameter of the enameled wire.

[0040] like Figure 5 and Figure 6 The wire feed tension system shown includes a tension wheel module 6. The axes of the three tension wheels in this module are aligned with the axis of the iron rod 2. The tension wheels detect tension via tension sensors and provide feedback to a controller. The controller uses a PID algorithm to control the speed of the tension wheels to maintain the tension between the enameled wire and the tension wheels at a set value.

[0041] like Figure 7 and Figure 8 As shown, the shape limiting system includes the aforementioned second slide 4, a steering gear 5, and a shape selection lever. The second slide 4 is placed vertically, with its movable platform perpendicular to the axis of the iron rod 2 and facing rightward. It is fixedly connected to the first slide 3. The steering gear 5 is connected to the movable platform of the second slide 4.

[0042] The shape selector lever is connected to the servo and moves in a plane perpendicular to the two axes of the iron rod. The various shape molds are mounted on the shape selector, with a pressure sensor attached to its base. The pressure sensor is connected to a processor, which provides feedback and controls the pressure signal. The processor controls the movement of the first slide until the pressure reaches a set value, ensuring tension is maintained during subsequent coil winding. When the slide descends to a point where the pressure sensor reading exceeds the set value, the automatic winding machine for the internal coils of the track blocks stops descending to accommodate the height change caused by the increasing number of coil layers during winding.

[0043] The following will further explain this product in conjunction with specific implementation plans.

[0044] First, remove the iron rod 2, fix the coil track to be wound on the middle part of the iron rod 2, pull the enameled wire through the tension wheel module 6, pre-wrap two circles to determine the winding direction, fix the starting point of the enameled wire, and use set screws to fix the two ends of the iron rod 2 to the servo motor 1 and the fixed frame respectively.

[0045] Secondly, according to the fixed position of the coil track to be wound, read the corresponding scale below, set the path coordinates to be wound on the controller's touch screen, install the required shape mold on the shape selection rod, and insert the number of the mold to be switched in front of each path coordinate according to the installed number.

[0046] Again, set the required tension in the menu on the display screen and set the required and appropriate winding speed according to the prompted limit range.

[0047] Then, press the "Home Position" button in the menu. After it returns to its home position, click the "Start Winding" button. After a short wait, the automatic winding machine for the internal coil of the track block will wind the coil set by the user.

[0048] Finally, the automatic winding machine for the internal coil of the track building block will automatically rise after the winding operation is completed. The fixing screws at both ends of the iron rod 2 are loosened and the track to be wound with the coil is removed, and the winding is completed.

[0049] If an error occurs during the winding process, the emergency stop button can be pressed. The automatic winding machine will retract the coil along the original path according to the current position and return to the pre-wound state. At the same time, the red light will flash continuously to remind the user that any further operation of the winding machine is prohibited during this period.

[0050] In this invention, to further enhance the user experience, a customizable indicator light is added. This indicator light is designed for diverse purposes, including, but not limited to, providing prompts indicating when a moving object has passed and indicating the effects of deceleration. The addition of this indicator light is intended to increase user interactivity with the device, thereby improving overall user satisfaction. The integration of this feature is considered readily achievable by those skilled in the art based on conventional techniques and existing knowledge, allowing for customization based on specific product requirements and design preferences.

[0051] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. Automatic winding machine for internal coils of track building blocks, including wire feeding tension system and track motion system, characterized by It also includes a synchronous control system and a shape limiting system, wherein the synchronous control system includes a second servo motor, a first slide (3) and a screw platform carrying a wire feeding tension system, and the synchronous control system receives input instructions from a processor to achieve matching of the coil diameter with the straight enameled wire stroke; the shape limiting system includes a servo (5) and a shape selection rod arranged on the second slide (4), and the second slide is arranged vertically; the first slide (3) is connected to the second slide through a connecting piece and a tension wheel module, and the enameled wire to be wound is kept on a vertical plane through the tension wheel module; the track motion system includes a first servo motor (1), and the first servo motor is connected to a horizontal iron rod (2) that fixes the track of the coil to be wound; The processor obtains the servo motor encoder value of the track motion system, and combines the servo motor line number, reduction ratio and the track radius of the coil to be wound to obtain the number of orbital motion circles of the coil to be wound. The calculation formula is as follows: Where N is the number of turns, L is the path length, P is the number of encoder pulses, R is the encoder resolution, i is the reduction ratio, and d is the diameter of the enameled wire.

2. The automatic winding machine for the internal coil of the track building block according to claim 1, characterized in that The servo (5) receives the PWM signal value transmitted by the processor according to the required mold shape, and changes the angle of its own steering wheel to cooperate with the orbital motion system to wind different coil shapes.

3. The automatic winding machine for the internal coil of the track building block according to claim 1 or 2, characterized in that The steering gear (5) is connected to the movable platform of the second slide (4), the shape selection rod is connected to the steering gear, the shape mold is installed on the shape selection rod, and a pressure sensor is attached to the bottom of the shape mold.

4. The automatic winding machine for the internal coil of the track building block according to claim 1 or 2, characterized in that The first servo motor (1) is arranged at the outermost side of the winding machine and is connected to an iron rod (2) on which a track for the coil to be wound is placed via a set screw.

5. The automatic winding machine for the internal coil of the track building block according to claim 4, characterized in that The starting end of the iron rod (2) is provided with a screw hole (7) for placing a set screw, the middle end is a smooth round rod for placing the coil track to be wound, and the tail end is a threaded rod (8) for tightening the nut of the coil track to be wound.

6. The automatic winding machine for the internal coil of the track building block according to claim 1, characterized in that The wire feeding tension system comprises a tension wheel module (6), and the tension wheel module (6) comprises at least three tension wheels arranged side by side.

7. The automatic winding machine for the internal coil of the track building block according to claim 6, characterized in that The processor controls the rotation speed of the tension wheel through a PID algorithm to stabilize the tension between the enameled wire and the tension wheel to a set value.

8. The automatic winding machine for the internal coil of the track building block according to claim 7, characterized in that The first servo motor (1), the second servo motor, the first slide (3), the second slide (4) and the tension wheel module (6) simultaneously feed back various operating parameters to the processor and receive motion signals processed by the processor.

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