Flat wire multi-connected cylindrical coil forming method

Abstract

An artificial intelligence (AI) technology is utilized, based on big data support, a special camera arranged at an intersection is matched, and through professional intelligent management software (additionally applying for software copyright), before the intersection is about to be congested, the congestion situation which will occur is pre-judged, two winding machine heads are arranged when a pre-winding duplex coil is called, and the rotation directions of the two machine heads are opposite; a bending sliding block capable of vertically sliding in the longitudinal direction is arranged on a main shaft of the second machine head. The bending sliding block is accurately designed according to the sizes of the coils and the center distance between the two coils, and the center distance between the two coils can be ensured to be within the required size range by accurately controlling the length and the angle of the reserved wire. The winding machine head 1 at the front position rotates clockwise to wind a first coil, and the first coil is stacked downwards; after winding of the first coil is completed, the first coil is transferred to a second winding machine head at the rear position to be wound with a second coil; the rotating direction of the winding machine head 2 is opposite to that of the winding machine head 1, a linear guide rail capable of vertically sliding is designed on the main shaft, and a bending sliding block is mounted on the guide rail; the wound first coil is upwards bent to be tightly attached to the bending sliding block, then is fixed to the bending sliding block through a coil lock and rotates along with a main shaft of the winding machine head 2; the winding machine head 2 rotates in the direction opposite to that of the winding machine head 1, a second coil is wound upwards in a stacked mode, and winding of the second coil is started from the connecting position of the two coils; after winding of the second coil is completed, traceless leveling needs to be conducted on bends at the connecting position; and after leveling, forming processing of the flat wire cylindrical duplex coil is completed.

Description

Technical Field

[0001] The invention relates to a method for forming a flat wire coil, in particular to a method for forming a flat wire multi-connected cylindrical coil. Background Art

[0002] Flattening the coil wire can greatly improve the window utilization of the coil and improve the heat dissipation efficiency of the coil. It is an inevitable trend in the development of electromagnetic coils.

[0003] Flat wire coils are mainly divided into two categories: round coils and special-shaped coils. Flat wire round coils are the most widely used and the quantity is very huge. The processing and forming methods of this type of coils are the focus of attention in the industry.

[0004] Currently, the most advanced method for processing and forming flat wire double-connected cylindrical coils is to set up two winding heads on the same horizontal plane. After the No. 1 head has completed winding the No. 1 coil, the clamping device installed on the horizontal linear guide rail is used to clamp the coil and stretch the wire in the opposite direction of the incoming wire to a certain length (the length is related to the diameter and number of turns of the coil). Then, the No. 2 head is used to start winding the No. 2 coil from the end of the reserved wire. Although this method has a high degree of automation and a fast processing speed, and has considerable technical advantages, it has to be pulled away for several meters after the No. 1 coil is wound, which requires a large production site; and the center distance control accuracy of the two coils is not high; it is impossible to wind multiple coils. Summary of the invention

[0005] The present invention is composed of a plurality of winding heads, the number of which is the same as the number of coils to be processed (two heads for a double coil, three heads for a triple coil, four heads for a quadruple coil...), the working planes of the winding heads are in the same horizontal plane, there is a certain misalignment in the X direction and the Y direction, the magnitude of the misalignment is related to the maximum diameter of the wound coil, usually the misalignment in the X direction is greater than 4 times the maximum diameter of the coil, and the misalignment in the Y direction is greater than 2 times the maximum diameter of the coil.

[0006] The corresponding winding machine heads are set according to the number of multi-connected coils. Two winding machine heads are set when winding double coils, and the rotation directions of the two machine heads are opposite. A bending slider that can slide vertically along the longitudinal direction is set on the main shaft of the No. 2 machine head. The bending slider is precisely designed according to the size of the coil and the center distance between the two coils. By precisely controlling the length and angle of the reserved wire, the center distance of the two coils can be guaranteed to be within the required size range.

[0007] The two coils use two flat wires of the same specifications. The two wires are on the same horizontal working surface and both need to be straightened and shaped first.

[0008] The front winding head 1 rotates clockwise to wind coil No. 1, and coil No. 1 is stacked downward; after coil No. 1 is wound, it is moved to the rear winding head 2 to wind coil No. 2; the rotation direction of winding head 2 is opposite to that of winding head 1, and a linear guide rail that can slide vertically is designed on the main shaft, and a bending slider is installed on the guide rail; the wound coil No. 1 is bent upward until it fits tightly with the bending slider, and then fixed on the bending slider with a coil lock, and rotates with the main shaft of winding head 2; winding head 2 rotates in the opposite direction to winding head 1, and coil No. 2 is stacked upward, and the winding of coil No. 2 starts from the place where the two coils are connected; after coil No. 2 is wound, the bend at the connection needs to be seamlessly flattened; after flattening, the forming process of the flat wire cylindrical double coil is completed.

[0009] The technical key of the present invention is: The two winding heads rotate in opposite directions; Coil 1 is stacked downwards, and coil 2 is stacked upwards; The wound No. 1 coil is bent and fixed to the bending slider using the bending slider; The bending slide slides vertically up and down the main shaft of the winding machine head 2 along the linear guide rail; The wound double coil needs to be leveled without leaving any mark.

[0010] The technical features and application advantages of the present invention are as follows: The center distance of the double coils can be precisely controlled; Save production space and improve the utilization rate of production space; According to the needs, the same process can be used to process triple coils, quadruple coils, etc. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The present invention is further described in detail below in conjunction with the accompanying drawings.

[0012] Attached Figure 1 This is a schematic diagram of a flat wire double cylindrical coil applicable to the present invention: Ⅰ——Coil 1, Ⅱ——Coil 2, 1——Tinned part on the end.

[0013] Figure 2 This is a schematic diagram of a multi-connected coil applicable to the present invention: α——Triple circular coil, Ⅰ——Coil 1, Ⅱ——Coil 2, III——Coil 3, 1——Tinned part on the end, β——Quadruple circular coil, Ⅰ——Coil 1, Ⅱ——Coil 2, III——Coil 3, IV——Coil 4.

[0014] Figure 3 This is a schematic diagram of the double cylindrical coil forming method of the present invention: Ⅰ——Coil 1, Ⅱ——Coil 2, 1——Tinned part on the end, 2——The No. 1 conductor after straightening and shaping, 3——The No. 2 conductor after straightening and shaping, 4——No. 1 machine head (clockwise rotation when viewed from above), 5——No. 2 machine head (rotates counterclockwise when viewed from above), 6——Coil bending slider, 7——Bending block slide.

[0015] Figure 4 This is a schematic diagram of the coil bending slider structure of the present invention: 7——Bending slider, 7-1——Chute bar, 7-2——Coil positioning table, 7-3——Coil lock fixing mortise, D——coil positioning table diameter (matched with coil diameter), 8——Coil lock, 8-1——Coil lock fixing tenon, 8-2——Coil pressure plate, L – Coil lock height (matched with coil height).

[0016] Figure 5 Schematic diagram of seamless leveling of the coil bending part 1——Tinned part on the end, 1-1——Bending and seamless shaping area.

Claims

1. A method for forming a multi-linked round coil of a flat conductor, characterized in that: The present invention can wind multi-connected cylindrical coils of flat wires, and is mainly used for the winding processing of double-connected cylindrical coils of flat wires; two winding heads are used when processing the double-connected coils; the rotation directions of the two winding heads are opposite; a linear slide rail for vertical sliding of a bending slider is designed on the winding head in the latter order, and the bending slider can move up and down in the vertical direction along the slide rail; coil No. 1 and coil No. 2 of the double-connected coil are respectively wound with two straight and shaped flat wires; coil No. 1 wound first is stacked downward, and coil No. 2 wound later is stacked upward; coil No. 1 is bent to a position close to the bending slider, and is fixed on the bending slider with a coil lock; the bending slider rotates with the winding head, and moves upward as the coil thickens; after the winding of coil No. 2 is completed, the bending part of the coil is leveled without a mark, so as to obtain a double-connected cylindrical coil with two parallel axes and a precise tangent center distance.

2. The invention according to claim 1 can be used to wind a multi-connected cylindrical coil of a flat conductor, wherein: Using the same process, double coils, triple coils, quadruple coils... and multiple coils can be wound.

3. The method of claim 1 wherein two winding heads are used for processing a double coil, wherein: There is a certain misalignment between the two winding heads in the X and Y directions. The size of the misalignment is related to the maximum diameter of the wound coil. Usually, the misalignment in the X direction is more than 3 times the maximum diameter of the coil, and the misalignment in the Y direction is more than 2 times the maximum diameter of the coil.

4. The No. 1 coil and No. 2 coil of the double coil according to claim 1 are respectively wound with two straight and shaped flat wires, characterized in that: The two conductors have the same specifications, are straightened and shaped, and are on the same horizontal working surface.

5. The first coil wound first is stacked downwards and the second coil wound later is stacked upwards according to claim 1, characterized in that: Typically, coil 1 is wound clockwise and stacked downward, and coil 2 is wound counterclockwise and stacked upward.

6. The winding machine head at the rear of claim 1 is designed with a linear slide rail for the bending slider to slide vertically, characterized in that: The linear slide rail designed on the main shaft of the winding machine head which is in the latter order of winding coil No. 2 is parallel to the axis of the machine head, and the bending slider can move vertically up and down along the slide rail, and the slide rail and the bending slider rotate with the winding machine head.

7. The No. 1 coil is fixed on the bending slider by a coil lock according to claim 1, characterized in that: The bending slider and coil lock are precisely designed according to the diameter, height, length and angle of the connecting wire between the coils. The coil lock and the bending slider are combined with a quick locking mechanism, which can be locked quickly and reliably, and can also be quickly unlocked. The most commonly used structure is a rotating buckle structure.

8. The No. 1 coil according to claim 1 is bent to a position close to the bending slider and fixed to the bending slider by a coil lock, wherein: The shape and size of the bending slider must be precisely designed according to the center distance of the coil. The tight fit between coil No. 1 and the bending slider can ensure the size and angle of the bending part.

9. The method for performing seamless flattening on the bend of the coil according to claim 1, characterized in that: After the No. 2 coil is wound, the bend needs to be leveled without leaving any marks. The leveling can be done manually, or by using a specially designed leveling device for mechanized leveling or automated leveling.

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