Coil forming mechanism and high-current inductor assembly equipment

Abstract

This invention provides a coil forming mechanism and a high-current inductor assembly device, relating to the field of inductor coil assembly technology. The coil forming mechanism includes a movable fixture module for moving a fixture carrying the coil, a bending module in front, and a cutting module behind. The bending module is used to bend the coil on the fixture. The movable fixture module also has a bending die that moves with the fixture. For coils with a wire thickness greater than 1mm, this invention prevents the coil from shifting during bending and cutting because the adjusting positioning module provides support from below, ensuring consistent cutting lengths and thus guaranteeing flatness after assembly and improving the welding stability of the inductor. Furthermore, since the adjusting positioning module can be adjusted vertically, it can accommodate coils of different thicknesses, overcoming the shortcomings of existing technologies where the flatness of the coil after forming cannot be met, and also overcoming the defect of exposed copper caused by damage to the outer mold of the coil, which affects performance.

Description

Technical Field

[0001] This invention relates to the field of inductor coil assembly technology, and in particular to a coil forming mechanism and a high-current inductor assembly device. Background Technology

[0002] Flat coil inductors, with their thin profile, large conducting area, high current capacity, and ease of assembly, are widely used in consumer electronics products. Typically, these inductors connect to the electronic circuitry of a product or system, contributing to current limiting. A flat coil inductor has a core pillar surrounded by a flat copper wire induction coil, with two leads for circuit connection. The leads are typically bent into a right-angle hook shape, requiring three steps to form: bending, breaking, and bending again. Only after the third bending step does the lead finally achieve its concave right-angle hook shape.

[0003] Among flat coil inductors, there is a type called high-current coil inductor. The coil wire thickness of high-current coil inductor is >1mm. The leads of high-current coil inductor are soldered onto the circuit board. Especially in the automotive and new energy industries, the requirements for soldering stability are high. The length and flatness of the leads will affect the soldering.

[0004] Patent CN114653854B discloses a coil bending method, mainly for high-current inductors with coil wire thickness > 0.8mm. Due to the limitation of molding size, the split mold cavity structure is not strong enough and is prone to deformation during production, resulting in inconsistent lead lengths after molding. Patent CN104174785A discloses a similar method, which requires a force of > 1000N to complete the molding of products with wire thickness > 1mm, without considering the flatness problem caused by damage to the copper wire enameled film and springback. Summary of the Invention

[0005] In view of this, one of the objectives of the present invention is to provide a coil forming mechanism to solve the technical problems in the prior art where the thickness of the copper coil wire, the bending coefficient and the elasticity lead to large changes in the pins, and damage to the outer film of the coil causes exposed copper, which affects the performance.

[0006] The second objective of this invention is to provide a high-current inductor assembly device containing a coil forming mechanism.

[0007] To achieve one of the above objectives, the present invention provides a coil forming mechanism, comprising a fixture moving module for moving a fixture, an adjustment and positioning module, and a bending leg module and a cutting module arranged one in front of the other and one in back of each other, wherein:

[0008] The adjustment and positioning module includes two modules, located directly below the bending module and the cutting module, respectively. When the fixture moves to below the bending module along with the fixture moving module, the adjustment and positioning module provides upward support for the fixture. The fixture moving module is equipped with a bending module that moves with the fixture, and the bending module provides support for the coil on the fixture. The bending module bends the coil. When the fixture moves to below the cutting module along with the fixture moving module, the adjustment and positioning module provides upward support for the fixture, and the cutting module cuts the coil.

[0009] Optionally, the fixture moving module includes a fixture track and a shift fork module. The fixture track is used to place the fixture, and the shift fork module drives the fixture to slide on the fixture track.

[0010] Optionally, the shift fork module includes a first drive member, a shift fork plate, and a fork lug. The first drive member is driven to the fork lug via the shift fork plate. The fork lug is used to clamp the fixture. When the first drive member is activated, it drives the fixture to slide on the fixture track via the fork lug.

[0011] Optionally, the shift fork plate is provided with a plurality of paired fork lugs, the distance between the fork lugs corresponding to the distance between the bending leg module and the cutting module, and the bending leg module being disposed between adjacent fork lugs.

[0012] Optionally, the bending foot mold includes a second driving member, a bending foot slide rail, and a bending foot support block. The bending foot slide rail is fixedly disposed at the end of the shift fork plate, and the second driving member is disposed on the bending foot slide rail and drivenly connected to the bending foot support block.

[0013] Optionally, the second drive member is detachably connected to the bent foot support block.

[0014] Optionally, the adjustment and positioning module includes a third driving component and a positioning column, wherein the positioning column is vertically disposed below the fixture and is drivenly connected to the third driving component.

[0015] Optionally, the bending module includes a fourth driving component, a bending pre-compression block, and a roller. The fourth driving component is simultaneously driven and connected to both the bending pre-compression block and the roller. The bending pre-compression block is used to pre-compress the coil, and the roller is used to bend the leads of the coil.

[0016] Optionally, the cutting module includes a fifth driving member, a cutting pre-compression block, a sixth driving member, and a cutting blade, wherein the fifth driving member and the cutting pre-compression block are drivenly connected, and the sixth driving member and the cutting blade are drivenly connected.

[0017] To achieve the second objective mentioned above, the present invention provides a high-current inductor assembly device, including any of the coil forming mechanisms described above, and further including a magnetic core feeding vibratory plate, a magnetic core handling module, a coil core assembly module, and a unloading module.

[0018] The coil forming mechanism provided by this invention has the following technical effects:

[0019] This coil forming mechanism mainly consists of a moving fixture module, an adjustment and positioning module, a bending module, and a cutting module. The moving fixture module is used to move the fixture carrying the coil. The bending module is in front, and the cutting module is behind. The bending module is used to bend the coil on the fixture. The moving fixture module also has a bending die that moves with the fixture. When the bending module bends the coil, it provides support for the coil on the fixture. The cutting module is used to cut the leads, and the adjustment and positioning module is used to provide upward support to the fixture from below during bending and cutting. For coils with a wire thickness greater than 1mm, this invention provides support from below to the fixture via the adjusting positioning module, preventing the coil from shifting during bending and cutting, and ensuring consistent cutting length. This ensures flatness after assembly and improves the welding stability of the inductor. Furthermore, since the adjusting positioning module can be adjusted up and down, it can accommodate coils of different thicknesses. This overcomes the shortcomings of existing technologies where the flatness of the coil after forming cannot be met, and also overcomes the shortcomings of exposed copper caused by damage to the outer mold of the coil, which affects performance.

[0020] The high-current inductor assembly equipment provided by this invention has the following technical advantages:

[0021] This high-current inductor assembly equipment includes a coil forming mechanism, a core feeding vibratory plate, a core handling module, a coil core assembly module, and a unloading module. The coil forming mechanism enables automatic coil forming, automatic core feeding, automatic assembly, and automatic unloading, thereby improving the assembly efficiency of the coil inductor. Attached Figure Description

[0022] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0023] Figure 1 This is a schematic diagram of the overall structure of a preferred embodiment of the high-current inductor assembly equipment of the present invention;

[0024] Figure 2 yes Figure 1Another perspective three-dimensional structural diagram of the medium-to-high current inductor assembly equipment;

[0025] Figure 3 yes Figure 2 Schematic diagram of the enlarged structure at A in the middle;

[0026] Figure 4 yes Figure 1 A partial structural schematic diagram of a medium-to-high current inductor assembly equipment;

[0027] Figure 5 yes Figure 1 A schematic diagram of the coil forming mechanism in a medium-to-high current inductor assembly equipment;

[0028] Figure 6 yes Figure 5 A schematic diagram of the bent-leg module of the coil forming mechanism;

[0029] Figure 7 yes Figure 5 A schematic diagram of the cutting module of the coil forming mechanism.

[0030] in, Figures 1-7 :

[0031] 1. Coil forming mechanism; 11. Adjustment and positioning module; 111. Third drive component; 112. Positioning column; 12. Fixture moving module; 121. Feeding conveyor belt; 122. Fixture conveying track; 123. Fixture track; 124. Fixture return track; 125. Fork module; 1251. First drive component; 1252. Fork plate; 1253. Fork lug; 126. Flow cylinder; 13. Bent leg module; 131. Fourth drive component; 132. Roller; 133. Bent leg pre-compression block; 14. Cutting module; 141. Fifth drive component; 142. Cutting pre-compression block; 143. Sixth drive component; 144. Cutting blade; 15. Bent leg mold; 151. Second drive component; 152. Bent leg slide rail; 153. Connecting block; 154. Bent leg support block;

[0032] 2. Vibratory feeder for magnetic cores; 3. Magnetic core handling module; 4. Coil and magnetic core assembly module; 5. Unloading module; 6. Fixture; 7. Coil. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of the present invention more apparent, the technical solutions of the present invention will be described in detail below. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other implementations obtained by those of ordinary skill in the art without inventive effort are within the scope of protection of the present invention.

[0034] Based on the shortcomings of existing technologies, the following section combines specific examples. Figure 1-7 A detailed description is given of the high-current inductor assembly equipment and its internal structure, the coil forming mechanism 1.

[0035] like Figure 1 and Figure 2 As shown, this invention provides a high-current inductor assembly device, including a coil forming mechanism 1, a magnetic core feeding vibratory plate 2, a magnetic core transport module 3, a coil core assembly module 4, and a unloading module 5. The coil 7 is first bent and cut by the coil forming mechanism 1. The magnetic core is placed on the magnetic core feeding vibratory plate 2, transported by the magnetic core transport module 3, and then assembled with the magnetic core by the coil core assembly module 4. Finally, the finished product is conveyed outward by the unloading module 5.

[0036] The following is a specific example. Figure 3-7 The coil forming mechanism 1 of the present invention will be described in detail.

[0037] like Figure 5 The diagram shown is a structural schematic of a preferred embodiment of the coil forming mechanism 1. The coil forming mechanism 1 includes a fixture moving module 12, an adjustment and positioning module 11, a bending die group 13, and a cutting module 14.

[0038] like Figure 4 As shown, the adjustment and positioning module 11 of this embodiment includes two modules. One adjustment and positioning module 11 is located directly below the bending die 15 group 13, and the other adjustment and positioning module 11 is located directly below the cutting module 14. The fixture 6 is positioned by adjusting the positioning module 11, thereby positioning the coil 7 placed in the fixture 6, which facilitates bending and cutting of the coil 7.

[0039] Specifically, when the fixture 6 containing the coil 7 moves with the fixture moving module 12 to below the bending die group 13, the adjusting positioning module 11 provides upward support for the fixture 6. The fixture moving module 12 is equipped with a bending die 15 that moves with the fixture 6. The bending die 15 provides support for the coil 7 on the fixture 6, and the bending die group 13 bends the coil 7. When the fixture 6 containing the coil 7 moves with the fixture moving module 12 to below the cutting module 14, the adjusting positioning module 11 provides upward support for the fixture 6, and the cutting module 14 cuts the bent coil 7.

[0040] For coils 7 with a wire thickness greater than 1mm, the present invention provides upward support to the fixture 6 from below by adjusting the positioning module 11, thus preventing the coil 7 from shifting when it is bent and cut by the bending die 15 group 13 and the cutting module 14, and ensuring the consistency of the cutting length, thereby ensuring the flatness after assembly and improving the welding stability of the inductor. At the same time, since the positioning module 11 can be adjusted up and down, it can adapt to coils 7 of different thicknesses.

[0041] Further, such as Figure 5 As shown, the fixture moving module 12 includes a fixture track 123, a fixture return track 124, a fixture conveying track 122, a transfer cylinder 126, a loading conveyor belt 121, and a shift fork module 125. The loading conveyor belt 121, the fixture conveying track 122, the fixture track 123, and the fixture return track 124 are connected end to end to form a closed loop, thereby realizing the movement of the fixture 6 containing the coil 7. The fixture 6 containing the coil 7 is driven by the transfer cylinder 126 on the fixture conveying track 122 and the fixture return track 124, and is driven by the shift fork module 125 on the fixture track 123.

[0042] The fixture track 123 has a shift fork module 125, which drives the fixture 6 with coil 7 to slide on the fixture track 123, such as... Figure 5 As shown, the shift fork module 125 of this embodiment includes a first driving member 1251, a shift fork plate 1252, and a fork lug 1253. The fork lugs 1253 are arranged in pairs, with a certain distance between the two fork lugs 1253, which is the length of the fixture 6. The paired fork lugs 1253 are distributed on the left and right ends of the fixture 6 to hold the fixture 6, thereby realizing the sliding of the fixture 6 on the fixture track 123.

[0043] Continue to see Figure 5 As shown, a fork plate is installed on the first driving member 1251, and a pair of fork lugs 1253 are installed along the length of the fork plate. The fork plate 1252 is driven to connect with the fork lugs 1253. The fork lugs 1253 are used to clamp the fixture 6. The first driving member 1251 drives the fork plate to move back and forth, which in turn drives the fork lugs 1253 to move, thereby driving the fixture 6 containing the coil 7 to move back and forth on the fixture track 123.

[0044] It should be noted that the first driving component 1251 in this embodiment can be a cylinder or a linear motor. As long as it can provide driving force for the fork plate to move back and forth, it is within the protection scope of this invention.

[0045] Meanwhile, in this embodiment, the distance between the paired fork lugs 1253 corresponds to the distance between the bending die group 15 13 and the cutting die group 14. In this way, when the previous jig 6 containing the coil 7 is bent, the next jig 6 containing the coil 7 is cut. The bending and cutting of different jigs 6 containing the coil 7 are carried out simultaneously, which improves the forming efficiency of the coil 7.

[0046] like Figure 3 and Figure 5 As shown, the bending foot mold 15 is disposed between a pair of adjacent fork lugs 1253. The bending foot mold 15 in this embodiment includes a second driving member 151, a bending foot slide rail 152, and a bending foot support block 154. The bending foot slide rail 152 is fixedly disposed at the end of the shift fork plate 1252, that is, the shift fork plate can drive the bending foot slide rail 152 to move to a certain extent. The second driving member 151 is located on the bending foot slide rail 152 and is drivenly connected to the bending foot support block 154. The second driving member 151 is drivenly connected to the bending foot support block 154 through the connecting block 153, that is, the second driving member 151 can drive the bending foot support block 154 to slide on the bending foot slide rail 152. The bending foot support block 154 slides, thereby achieving support for the coil 7 to be bent.

[0047] Here, the support of the bending foot support block 154 for the bending coil 7 refers to the fact that the two pins of the coil 7 are of different heights. The lower pin can be supported by the fixture 6, while the higher pin, since it does not contact the fixture 6 from below, cannot provide support for the pin when the bending foot mold group 1513 bends the pins of the coil 7. Therefore, the bending foot mold 15 is used. The bending foot mold 15 is inserted below the higher pin to form support for the pin, thereby realizing the bending of the pins of the bending foot mold group 1513.

[0048] Furthermore, the second drive member 151 of this embodiment is detachably connected to the bent foot support block 154. The detachable connection is preferably a snap-fit ​​connection, whereby the bent foot support block 154 is snapped onto the connecting block 153. By snapping the bent foot support block 154 onto the connecting block 153, it is convenient to replace different bent foot support blocks 154 to adapt to different models of coils 7.

[0049] It should be noted that the second driving component 151 in this embodiment can be a cylinder or a linear motor. As long as it can provide driving force for the forward and backward movement of the bent foot support block 154, it is within the protection scope of this invention.

[0050] More specifically, such as Figure 4 As shown, the adjustment and positioning module 11 of this embodiment includes a third driving member 111 and a positioning post 112. The positioning post 112 is vertically disposed below the fixture 6 and is drivenly connected to the third driving member 111.

[0051] The third drive member 111 provides an upward driving force to the positioning post 112, pressing against the fixture 6 from below, and thus providing support for the coil 7 from below during bending and cutting.

[0052] It should be noted that the third driving component 111 in this embodiment can be a cylinder or a linear motor. As long as it can provide the driving force for the positioning column 112 to move upward, it is within the protection scope of this invention.

[0053] As a preferred embodiment, such as Figure 6 As shown, the bending die 15 group 13 includes a fourth driving member 131, a bending pre-pressing block 133 and a roller 132. The fourth driving member 131 is simultaneously driven and connected to the bending pre-pressing block 133 and the roller 132. The bending pre-pressing block 133 is used to pre-press the coil 7, and the roller 132 is used to bend the pin of the coil 7.

[0054] The bending foot pressure block here presses down on the coil 7 from above, while the two rollers 132 are used to bend the two pins of the coil 7, with one pin at a higher position and the other at a lower position.

[0055] It should be noted that the fourth driving component 131 in this embodiment can be a cylinder or a linear motor. As long as it can provide a downward driving force for the bent foot pressing block and the roller 132, it is within the protection scope of this invention.

[0056] As a preferred embodiment, such as Figure 4 and Figure 7 As shown, the cutting module 14 includes a fifth driving member 141, a cutting pre-pressing block 142, a sixth driving member 143, and a cutting blade 144. The fifth driving member 141 and the cutting pre-pressing block 142 are drivenly connected, and the fifth driving member 141 can drive the cutting pre-pressing block 142 to move downward. The sixth driving member 143 and the cutting blade 144 are drivenly connected, and the sixth driving member 143 can drive the cutting blade to move in the direction of the coil 7.

[0057] Here, the pre-pressing block 142 presses down on the coil 7 from above, while the cutting blade 144 is used to cut the pins of the coil 7.

[0058] It should be noted that the fifth driving member 141 and the sixth driving member 143 in this embodiment can be a cylinder or a linear motor. As long as they can provide the driving force for the cutting top pressure block and the cutting blade 144 to move downward and laterally, they are all within the protection scope of this invention.

[0059] In the description of this invention, it should be noted that, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this 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 this invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0060] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0061] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present invention should be included in the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. A coil forming mechanism, characterized in that, This includes a fixture moving module, an adjustment and positioning module, and a bending leg module and a cutting module set one in front of the other, wherein: The adjustment and positioning module includes two modules, located directly below the bending module and the cutting module, respectively. When the fixture moves to below the bending module along with the fixture moving module, the adjustment and positioning module provides upward support for the fixture. The fixture moving module is equipped with a bending module that moves with the fixture, and the bending module provides support for the coil on the fixture. The bending module bends the coil. When the fixture moves to below the cutting module along with the fixture moving module, the adjustment and positioning module provides upward support for the fixture, and the cutting module cuts the coil. The fixture moving module includes a fixture track and a shift fork module. The fixture track is used to place the fixture, and the shift fork module drives the fixture to slide on the fixture track. The shift fork module includes a first driving member, a shift fork plate, and a fork lug. The first driving member is driven to be connected to the fork lug through the shift fork plate. The fork lug is used to clamp the fixture. When the first driving member is activated, it drives the fixture to slide on the fixture track through the fork lug. The shift fork plate is provided with a number of paired fork lugs, the distance between the fork lugs corresponds to the distance between the bent leg module and the cutting module, and the bent leg module is provided between adjacent fork lugs; The adjustment and positioning module includes a third driving component and a positioning column. The positioning column is vertically disposed below the fixture and is drivenly connected to the third driving component.

2. The coil forming mechanism according to claim 1, characterized in that, The bent foot mold includes a second driving component, a bent foot slide rail, and a bent foot support block. The bent foot slide rail is fixedly mounted on the end of the shift fork plate, and the second driving component is mounted on the bent foot slide rail and is drivenly connected to the bent foot support block.

3. The coil forming mechanism according to claim 2, characterized in that, The second drive component is detachably connected to the bent foot support block.

4. The coil forming mechanism according to any one of claims 1-3, characterized in that, The bent-leg module includes a fourth driving component, a bent-leg pre-pressing block, and a roller. The fourth driving component is simultaneously driven and connected to the bent-leg pre-pressing block and the roller. The bent-leg pre-pressing block is used to pre-press the coil, and the roller is used to bend the leads of the coil.

5. The coil forming mechanism according to any one of claims 1-3, characterized in that, The cutting module includes a fifth driving component, a cutting pre-compression block, a sixth driving component, and a cutting blade. The fifth driving component and the cutting pre-compression block are drivenly connected, and the sixth driving component and the cutting blade are drivenly connected.

6. A high-current inductor assembly device, characterized in that, The coil forming mechanism according to any one of claims 1-5 further includes a magnetic core feeding vibratory plate, a magnetic core handling module, a coil core assembly module, and a unloading module.

Images