Winding machine and pinhole detection and nozzle flaw detection method

Abstract

The invention relates to the field of motor production and manufacturing, and discloses a winding machine which comprises a winding machine body, a pinhole detection module and a wire nozzle flaw detection module are arranged on the winding machine body, and the pinhole detection module comprises a detection control module and a pinhole detection mechanism which are matched with each other. The wire nozzle flaw detection module comprises a flaw detection control module and a wire nozzle mechanism which are matched with each other, and an enameled wire sequentially penetrates through a pinhole detection mechanism of the pinhole detection module and the wire nozzle mechanism of the wire nozzle flaw detection module and then is wound on an iron core of a stator to form a winding. Whether pinholes exist in the insulating layer of the enameled wire or not can be judged through the detection control module, whether the insulating layer is damaged or not is detected through the flaw detection control module, then the online detection function of the enameled wire is achieved, the detection efficiency is improved, and meanwhile products cannot be damaged.

Description

Technical Field

[0001] The invention relates to the field of motor production and manufacturing, and in particular to a winding machine and a method for pinhole detection and wire nozzle flaw detection. Background Art

[0002] With the continuous improvement of the production process of enameled wire, the quality of the insulation layer of enameled wire has also been continuously improved; however, due to process limitations, it is still impossible to eliminate the existence of pinholes in the insulation layer. During the production process of enameled wire, due to various factors, tiny pinholes may appear on the paint film. These pinholes will destroy the insulation performance of the enameled wire, causing short circuits, leakage and other problems during use, seriously affecting the normal operation and safety of electrical equipment.

[0003] However, existing winding machine equipment is unable to achieve real-time monitoring of enameled wire pinholes and the damage of the enameled wire insulation layer during the production process caused by the winding process, tooling or parts; therefore, motor products need to undergo subsequent salt water pinhole detection to confirm the damage of the enameled wire. Through pinhole detection, enameled wires with pinhole defects can be discovered and removed in time to ensure product quality.

[0004] However, this type of testing is destructive and cannot be fully inspected, so online testing of enameled wire becomes very important. Summary of the invention

[0005] The purpose of the present invention is to overcome the deficiencies in the prior art and to provide a winding machine on which a pinhole detection module and a wire nozzle flaw detection module are arranged to realize online detection of the enameled wire; the number of pinholes in the enameled wire can be monitored in real time during the winding process of the motor stator, and whether the wire nozzle causes damage to the insulating layer of the enameled wire can also be monitored in real time; the quality of the stator winding can be identified in real time, which plays an important role in improving the winding process of the motor stator product.

[0006] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a winding machine, including a winding machine body, on which a pinhole detection module and a wire nozzle flaw detection module are arranged, the pinhole detection module includes a detection control module and a pinhole detection mechanism that cooperate with each other, the wire nozzle flaw detection module includes a flaw detection control module and a wire nozzle mechanism that cooperate with each other, and the enameled wire passes through the pinhole detection mechanism and the wire nozzle mechanism in turn and is then wound on the iron core of the stator to form a winding.

[0007] Optionally, the pinhole detection mechanism comprises a container for containing a conductive solution, the container is fixedly mounted on the winding machine body, and two liquid-absorbing components capable of opening and closing relative to each other are arranged inside the container; The bottom of the container is also provided with an electrode, and the lower end of the liquid-drawing component and the electrode are immersed in the conductive solution; Wherein, the head end of the enameled wire passes through between the two liquid-absorbing components, and the end of the enameled wire is connected to the electrode through a detection control module.

[0008] Optionally, the detection control module includes a detection power supply and a voltage sampling circuit, one end of the detection power supply is connected to the conductor of the enameled wire, and the other end is connected to the electrode through a first resistor; The electrode forms a third resistor with the conductor through the conductive solution and the insulating layer of the enameled wire. The voltage sampling circuit is connected in parallel with the third resistor, and a voltage comparator, a timer and a first counter are sequentially connected to the voltage sampling circuit.

[0009] Optionally, the nozzle mechanism includes a sleeve mounted on the winding machine body and a nozzle body in contact with the enameled wire, fixed pulleys are provided at both ends of the sleeve, and the enameled wire passes through the sleeve and the nozzle body in sequence and is then wound on the stator; Wherein, the end of the enameled wire and the wire nozzle body are connected through a flaw detection control module.

[0010] Optionally, the flaw detection control module includes a flaw detection power supply, a second resistor, a diode, a current sampling circuit, a wire nozzle body and an end of the enameled wire connected in series in sequence, and the current sampling circuit is also connected in sequence to an amplifier, a current comparator and a second counter; The insulating layer between the nozzle body and the conductor forms a fourth resistor, and when the insulating layer is damaged, the conductor is exposed and contacts the nozzle body.

[0011] Optionally, a drying module and a cleaning module are further provided on the winding machine body, and the enameled wire passes through the pinhole detection mechanism, the drying module and the cleaning module in sequence and then enters the wire nozzle mechanism.

[0012] Optionally, the drying module includes a shell connected to the winding machine body, the inner cavity of the shell is divided into independent blowing chamber, heating chamber and cooling chamber by two partitions, and the enameled wire passes through the blowing chamber, the heating chamber and the cooling chamber in turn and then enters the cleaning module.

[0013] Optionally, the cleaning module includes two sets of oppositely arranged take-up wheels and driven wheels, a cleaning belt is wound around the driven wheel, one end of the cleaning belt is passed around the tensioning wheel and wound around the take-up wheel, the enameled wire passes between the two cleaning belts, and a clamping assembly for driving the cleaning belt to contact the enameled wire is provided on one side of the tensioning wheel. The cleaning belt continuously changes position under the drive of the take-up wheel, and always keeps the clean surface in contact with the enameled wire.

[0014] A pinhole detection method comprises the following steps: S1, collecting the voltage across the third resistor through a voltage sampling circuit, and inputting it into a voltage comparator for comparison with the voltage of a detection power supply; S2. If V1≤(U1×R0 / (R0+R1)), the timer starts working for a time of τ; wherein V1 is the voltage across the third resistor, U1 is the voltage of the detection power supply, R1 is the resistance value of the first resistor, and R0=10kΩ; S3. If τ≥t, it is considered that a pinhole is found on the insulation layer of the enameled wire, and the first counter counts once; where t=5ms.

[0015] A method for detecting a wire mouth comprises the following steps: Step 1: The current flowing through the conductor is collected through the current sampling circuit, the amplified current signal is output through the amplifier, and then enters the current comparator for comparison with the set current value; Step 2: If I1≥Iset, it is considered that the insulation layer of the enameled wire is damaged once, and the second counter counts once; wherein I1 is the current signal output after being amplified by the amplifier, and Iset is the set current value.

[0016] Compared with the prior art, the present invention has the following beneficial effects: (1) In the present invention, the enameled wire passes through the pinhole detection mechanism of the pinhole detection module and the wire nozzle mechanism of the wire nozzle flaw detection module in sequence and is then wound around the stator core to form a winding. During this process, the detection control module can be used to determine whether there are pinholes on the insulation layer of the enameled wire, and the flaw detection control module can be used to detect whether the insulation layer is damaged, thereby realizing the online detection function of the enameled wire, improving the detection efficiency, and not causing damage to the product; (2) In the present invention, after the pinhole detection of the enameled wire, its surface will be stained with a solution; after passing through the blowing chamber, heating chamber and cooling chamber of the drying module in sequence, the moisture on its surface can be dried; and then passing through the cleaning belt of the cleaning module, the solute remaining on its surface can be removed, thereby ensuring that the winding wound on the stator core is dry and clean, and avoiding the normal performance of the motor stator being affected by the detection method. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a functional structure diagram of a winding machine in an embodiment of the present invention; Figure 2 is a schematic structural diagram of a winding machine in an embodiment of the present invention; Figure 3 is a schematic structural diagram of a pinhole detection mechanism in an embodiment of the present invention; Figure 4 is a schematic diagram of the structure of the detection and flaw detection control module in an embodiment of the present invention; Figure 5 is a structural schematic diagram of a drying module in an embodiment of the present invention; Figure 6 is a schematic structural diagram of a cleaning module in an embodiment of the present invention; Among them, 1. winding machine body; 2. enameled wire; 21. conductor; 22. insulating layer; 3. wire drum; 31. guide wheel; 32. bobbin; Detection control module: 401, detection power supply; 402, first resistor; 403, voltage sampling circuit; 404, voltage comparator; 405, timer; 406, first counter; Pinhole detection mechanism: 501, container; 502, first fixing plate; 503, clamping plate; 504, liquid-absorbing component; 505, first spring; 506, liquid level sensor; 507, electrode; 508, conductive solution; Flaw detection control module: 601, flaw detection power supply; 602, second resistor; 603, current sampling circuit; 604, amplifier; 605, current comparator; 606, second counter; 7. Wire nozzle mechanism; 701. sleeve; 702. fixed pulley; 703. wire nozzle body; 8. Drying module; 801. Shell; 802. Partition; 803. Air blowing cavity; 804. Heating cavity; 805. Cooling cavity; 806. Ceramic ring; 807. First blowing nozzle; 808. Heating wire; 809. Impeller; 810. Second blowing nozzle; 9. Cleaning module; 901. Take-up wheel; 902. Driven wheel; 903. Cleaning belt; 904. Tensioning wheel; 905. Second fixed plate; 906. Slide plate; 10. Stator; 11. Clamp. DETAILED DESCRIPTION

[0018] The present invention will now be further described in detail with reference to the accompanying drawings and embodiments. These drawings are simplified schematic diagrams that only illustrate the basic structure of the present invention in a schematic manner, and therefore only show the components related to the present invention.

[0019] The enameled wire 2 includes a conductor 21 and an insulating layer 22 wrapped around the outside of the conductor 21, and the enameled wire 2 is usually wound on a bobbin 32 and placed in a bobbin 3 for storage. A guide wheel 31 is installed on the top of the bobbin 3, and its function is to reduce the friction and wear of the insulating layer 22. The rolling friction generated by the guide wheel 31 and the enameled wire 2 is much smaller than the sliding friction generated by the direct contact between the enameled wire 2 and the bobbin 3.

[0020] After the head end of the enameled wire 2 is led out from the bobbin 3, it enters the wire nozzle of the winding machine through the fixed pulley group, the tensioner and the rocker arm in sequence, and then is wound on the iron core of the stator 10 through the wire nozzle, and the stator 10 is clamped on the winding machine through the clamp 11; and the head and tail ends of the enameled wire 2 can be electrically connected to the corresponding components.

[0021] Embodiment 1: Figure 1 , Figure 2 As shown, a winding machine includes a winding machine body 1, on which a pinhole detection module and a wire nozzle flaw detection module are arranged, the pinhole detection module includes a detection control module and a pinhole detection mechanism that cooperate with each other, and the wire nozzle flaw detection module includes a flaw detection control module and a wire nozzle mechanism 7 that cooperate with each other.

[0022] The enameled wire 2 passes through the pinhole detection mechanism of the pinhole detection module and the wire nozzle mechanism 7 of the wire nozzle flaw detection module in sequence and is then wound around the iron core of the stator 10 to form a winding. During this process, the detection control module can be used to determine whether there are pinholes on the insulating layer 22 of the enameled wire 2, and the flaw detection control module can be used to detect whether the insulating layer 22 is damaged, thereby realizing the online detection function of the enameled wire 2, thereby improving the detection efficiency and not causing damage to the product.

[0023] like Figure 3 As shown, the pinhole detection mechanism includes a container 501 for containing a conductive solution 508, the container 501 is fixedly mounted on the winding machine body 1, and the interior of the container 501 is provided with two liquid absorbing parts 504 that can be opened and closed relative to each other; an electrode 507 is also provided at the bottom of the container 501, and the lower end of the liquid absorbing part 504 and the electrode 507 are immersed in the conductive solution 508; the head end of the enameled wire 2 passes through between the two liquid absorbing parts 504, and the end of the enameled wire 2 is connected to the electrode 507 through the detection control module.

[0024] The conductive solution 508 may be a sodium chloride solution or a sodium sulfate solution, and the liquid absorbing component 504 preferably uses wool felt, which has good water absorption performance, and absorbs the conductive solution 508 into itself and then contacts the enameled wire 2, thereby achieving the immersion of the enameled wire 2 in the conductive solution 508. If pinholes appear on the insulating layer 22 of the enameled wire 2, the circuit of the detection control module is turned on, and detection counting is performed.

[0025] Regarding the relative opening and closing of the two liquid-absorbing components 504, two opposite first fixing plates 502 are fixedly installed in the container 501, and two clamping plates 503 are relatively arranged on the inner sides of the two first fixing plates 502. A first spring 505 is arranged between the clamping plate 503 and the first fixing plate 502, and the two liquid-absorbing components 504 are fixedly installed on the two clamping plates 503 respectively.

[0026] Among them, the first fixed plate 502 is fixed during the working process, but the compression amount of the first spring 505 can be adjusted by the distance between the first fixed plate 502 and the clamping plate 503, thereby achieving the purpose of adjusting the clamping force of the wool felt on both sides of the enameled wire 2, ensuring that the enameled wire 2 can be wrapped in the conductive solution 508.

[0027] Furthermore, a liquid level sensor 506 is provided in the container 501 for monitoring the amount of the conductive solution 508, and the remaining amount of the conductive solution 508 measured by the liquid level sensor 506 can be input to the pinhole detection module through a signal line; the container 501 is made of insulating material to ensure the safety of detection.

[0028] like Figure 4 As shown, the detection control module includes a detection power supply 401 and a voltage sampling circuit 403. One end of the detection power supply 401 is connected to the conductor 21 of the enameled wire 2, and the other end is connected to the electrode 507 through the first resistor 402; the electrode 507 forms a third resistor between the conductor 21 and the insulating layer 22 of the enameled wire 2 through the conductive solution 508, the voltage sampling circuit 403 is connected in parallel with the third resistor, and the voltage sampling circuit 403 is also connected in sequence to a voltage comparator 404, a timer 405 and a first counter 406.

[0029] The enameled wire 2 is surrounded by the conductive solution 508. When the insulating layer 22 of the enameled wire 2 is very intact, the resistance value of the third resistor is infinite. When there is a pinhole on the insulating layer 22 of the enameled wire 2, and when the pinhole is deep enough to expose the conductor 21 to contact the conductive solution 508 or when the conductor 21 is almost exposed, the resistance value of the third resistor is no longer infinite.

[0030] The end of the enameled wire 2 and the electrode 507 are both connected to the circuit in the detection control module, so the third resistor is connected to the circuit in the detection control module. The voltage U1 of the detection power supply 401 is 50V. The voltage sampling circuit 403 is used to collect the voltage V1 across the third resistor and input it into the voltage comparator 404 for comparison with the voltage of the detection power supply 401.

[0031] If V1≤(U1×R0 / (R0+R1)), the timer 405 starts working for a time of τ; if τ≥t, it is considered that a pinhole is found, and the first counter 406 counts once; wherein R1 is the resistance value of the first resistor 402, R0=10kΩ, t=5ms, and the first resistor 402 is used to protect the circuit. When the resistance value of the third resistor is close to 0Ω, it is ensured that short circuit burning does not occur.

[0032] like Figure 4As shown, the nozzle mechanism 7 includes a sleeve 701 installed on the winding machine body 1 and a nozzle body 703 in contact with the enameled wire 2, fixed pulleys 702 are provided at both ends of the sleeve 701, and the enameled wire 2 passes through the sleeve 701 and the nozzle body 703 in sequence and is then wound on the stator 10, and the end of the enameled wire 2 is also connected to the nozzle body 703 through a flaw detection control module.

[0033] The enameled wire 2 enters the wire nozzle mechanism 7 through the fixed pulley 702 at the upper end, passes through the sleeve 701, enters the fixed pulley 702 at the lower end, and then turns 90 degrees to enter the wire nozzle body 703. The wire nozzle body 703 reciprocates up and down along the axial direction of the stator 10, cooperates with the stator 10 and the fixed clamp 11 to reciprocate around the axial direction of the stator 10, and the enameled wire 2 is wound around the teeth of the stator 10 core to form a winding.

[0034] Except for the nozzle body 703, all parts that the enameled wire 2 passes through and contacts are covered with insulating materials; the nozzle body 703 is fixed on the nozzle mechanism 7, and the nozzle body 703 is insulated from all other parts on the nozzle mechanism 7; wherein, the nozzle body 703 is a conductor and is connected to the circuit of the flaw detection control module through wires, and the end of the nozzle body 703 contacts the enameled wire 2.

[0035] The flaw detection control module includes a flaw detection power supply 601, a second resistor 602, a diode, a current sampling circuit 603, a wire nozzle body 703 and the end of the enameled wire 2 which are connected in series in sequence, and the current sampling circuit 603 is also connected to an amplifier 604, a current comparator 605 and a second counter 606 in sequence; Among them, the insulating layer 22 between the wire nozzle body 703 and the conductor 21 forms a fourth resistor. Usually, the resistance of the fourth resistor is infinite. When the insulating layer 22 of the enameled wire 2 is damaged, the conductor 21 is exposed and contacts the wire nozzle body 703; the resistance of the fourth resistor is no longer infinite, the circuit of the flaw detection control module is connected, and the flaw detection counting work is performed.

[0036] When the resistance of the fourth resistor is infinite, the current I0 flowing through the conductor 21 is 0A; when the enameled wire 2 is scratched at the wire nozzle body 703, the resistance of the fourth resistor decreases and the circuit is turned on; at this time, the current sampling circuit 603 detects the current I0, outputs the amplified current signal I1 through the amplifier 604, enters the current comparator 605 and compares it with the set current Iset. If I1≥Iset, it is determined that the enameled wire 2 is damaged once, and the second counter 606 counts once.

[0037] Furthermore, the control system of the pinhole detection module and the wire nozzle flaw detection module also includes a display screen, an indicator light and a data uploading system, which can realize: real-time detection of pinhole damage of the enameled wire 2 on the winding machine; real-time monitoring of possible damage to the insulation layer 22 caused by winding at the wire nozzle; real-time feedback of the monitoring data to the operator, and binding and uploading the system with the stator 10 data.

[0038] In addition, the number of pinhole detection modules and wire nozzle flaw detection modules is the same as the number of axes of the winding machine body 1, that is, the same as the number of clamps 11 on the winding machine and the number of stators 10 that can be produced simultaneously; the pinhole detection mechanism and the detection control module work together to realize the real-time detection function of pinholes in the enameled wire 2; the wire nozzle mechanism 7 and the flaw detection control module work together to realize the real-time wire nozzle flaw detection function.

[0039] Embodiment 2: Based on embodiment 1, the present invention further proposes a drying module 8 and a cleaning module 9.

[0040] like Figure 1 , Figure 5 and Figure 6 As shown, the drying module 8 and the cleaning module 9 are both arranged on the winding machine body 1, and the enameled wire 2 passes through the pinhole detection mechanism, the drying module 8 and the cleaning module 9 in sequence and then enters the wire nozzle mechanism 7.

[0041] The drying module 8 includes a shell 801 connected to the winding machine body 1. The inner cavity of the shell 801 is divided into a blowing chamber 803, a heating chamber 804 and a cooling chamber 805 by two partitions 802. A wire passing hole is provided on the partition 802, and the enameled wire 2 passes through the blowing chamber 803, the heating chamber 804 and the cooling chamber 805 in turn through the wire passing hole and then enters the cleaning module 9.

[0042] A ceramic ring 806 and a group of first blowing nozzles 807 are provided in the blowing chamber 803. The enameled wire 2 passes through the ceramic ring 806 and passes through the middle of the first blowing nozzle 807. The first blowing nozzle 807 blows air continuously toward the enameled wire 2 to blow the residual conductive solution 508 away from the enameled wire 2; then the enameled wire 2 passes through the wire hole and enters the heating chamber 804.

[0043] A heating wire 808 and a rotating impeller 809 are provided in the heating chamber 804. The enameled wire 2 passes through the heating chamber 804. The heating wire 808 heats the internal air and stirs the air through the impeller 809 to heat the enameled wire 2, ensuring that the water component in the conductive solution 508 is fully volatilized; then the enameled wire 2 passes through the wire hole and enters the cooling chamber 805.

[0044] A ceramic ring 806 and a set of second blowing nozzles 810 are also provided in the cooling cavity 805. The enameled wire 2 passes through the ceramic ring 806 in the cavity, and the second blowing nozzle 810 continuously blows air to the enameled wire 2 to cool the enameled wire 2.

[0045] After the pinhole detection of the enameled wire 2, the surface thereof will be stained with a solution; after passing through the blowing chamber 803, the heating chamber 804 and the cooling chamber 805 of the drying module 8 in sequence, the moisture on the surface thereof can be dried.

[0046] The cleaning module 9 includes two sets of relatively arranged take-up wheels 901 and driven wheels 902, a cleaning belt 903 is wound around the driven wheel 902, one end of the cleaning belt 903 is passed around the tensioning wheel 904 and wound around the take-up wheel 901, the enameled wire 2 passes between the two cleaning belts 903, and a clamping assembly for driving the cleaning belt 903 to contact the enameled wire 2 is provided on one side of the tensioning wheel 904; and the cleaning belt 903 continuously changes its position under the drive of the take-up wheel 901, always keeping the clean surface in contact with the enameled wire 2, so as to ensure the cleaning effect of the enameled wire 2.

[0047] The cleaning belt 903 is also preferably made of wool felt. Two pieces of wool felt clamp the enameled wire 2 under the action of the clamping assembly, and slowly run in the direction opposite to the forward direction of the enameled wire 2, thereby cleaning the salt substances remaining on the enameled wire 2 after the conductive solution 508 evaporates.

[0048] Furthermore, the cleaning belt 903 is mounted on the driven wheel 902 in the form of a coil, and one end of the cleaning belt 903 is fixed on the take-up wheel 901. The take-up wheel 901 rotates to slowly pull the cleaning belt 903 from the driven wheel 902, and the moving direction of the cleaning belt 903 is opposite to the advancing direction of the enameled wire 2.

[0049] The tensioning wheel 904 pushes the cleaning belt 903 outward from the inside to tension it, and the clamping assembly clamps the two cleaning belts 903 from the middle to make them in close contact with the enameled wire 2.

[0050] The clamping assembly includes two slide plates 906 arranged opposite to each other, a second fixing plate 905 is arranged on the back side of the slide plate 906, and a second spring is arranged between the second fixing plate 905 and the slide plate 906, and the front side of the slide plate 906 is in contact with the cleaning belt 903. The second spring is in a compressed state, and based on the second fixing plate 905 giving a certain thrust to the slide plate 906, the cleaning belt 903 is pulled by the take-up wheel 901 and moves slowly in the opposite direction to the advancing direction of the enameled wire 2.

[0051] Among them, each group is equipped with two tensioning wheels 904, which are located on the left and right sides of the clamping assembly respectively; the dried enameled wire 2 passes through the cleaning belt 903 of the cleaning module 9 to remove the solutes remaining on its surface, avoiding the normal performance of the motor stator being affected by the detection method.

[0052] In addition, the number of drying modules 8 and cleaning modules 9 can be the same as the number of axes of the winding machine, that is, the same as the number of clamps 11 on the winding machine and the stators 10 that can be produced simultaneously, or all axes can share one drying module 8 and cleaning module 9.

[0053] Embodiment 3: Based on Embodiment 1, the present invention further proposes a pinhole detection method, comprising the following steps.

[0054] The voltage across the third resistor is collected by the voltage sampling circuit 403 and input into the voltage comparator 404 for comparison with the voltage of the detection power supply 401; the end of the enameled wire 2 and the electrode 507 are both connected to the circuit in the detection control module, so the third resistor is connected to the circuit in the detection control module, the voltage U1 of the detection power supply 401 is 50V, and the voltage sampling circuit 403 is used to collect the voltage V1 across the third resistor and input into the voltage comparator 404 for comparison with the voltage of the detection power supply 401.

[0055] If V1≤(U1×R0 / (R0+R1)), the timer 405 starts working for a time of τ; wherein V1 is the voltage across the third resistor, U1 is the voltage of the detection power supply 401, R1 is the resistance of the first resistor 402, and R0=10kΩ; the first resistor 402 is used to protect the circuit, and when the resistance of the third resistor is close to 0Ω, it can be ensured that short circuit burning does not occur.

[0056] If τ≥t, it is considered that a pinhole is found on the insulating layer 22 of the enameled wire 2, and the first counter 406 counts once; wherein t=5ms.

[0057] Embodiment 4: Based on embodiment 1, the present invention further proposes a wire nozzle flaw detection method, comprising the following steps.

[0058] Usually, the resistance of the fourth resistor is infinite. When the insulating layer 22 of the enameled wire 2 is damaged, the conductor 21 is exposed and contacts the nozzle body 703. The resistance of the fourth resistor is no longer infinite, the loop of the flaw detection control module is connected, and the flaw detection counting work is performed.

[0059] First, the current flowing through the conductor 21 is collected through the current sampling circuit 603, and the amplified current signal is output through the amplifier 604, and then enters the current comparator 605 for comparison with the set current value. When the resistance value of the fourth resistor is infinite, the current I0 flowing through the conductor 21 is 0A; when the enameled wire 2 is scratched at the wire nozzle body 703, the resistance value of the fourth resistor decreases, and the circuit is turned on; at this time, the current sampling circuit 603 detects the current I0.

[0060] If I1≥Iset, it is considered that the insulation layer 22 of the enameled wire 2 is damaged once, and the second counter 606 counts once; wherein I1 is the current signal output after being amplified by the amplifier 604, and Iset is the set current value.

[0061] In summary, the present invention adds a pinhole detection module and the associated drying module 8, cleaning module 9 and wire nozzle flaw detection module to the functions of the traditional winding machine; it can realize real-time detection of pinhole damage of the enameled wire 2 on the winding machine, and real-time monitoring of damage to the insulating layer 22 of the enameled wire 2 caused by winding that may occur at the wire nozzle, and the monitoring data is fed back to the operator in real time, and is bound to the stator 10 data and uploaded to the system.

[0062] In the process from the enameled wire 2 leaving the bobbin 32 to being finally wound on the core of the stator 10 to form a winding, the functional modules that directly contact the enameled wire 2 in the forward direction include a fixed pulley block, a pinhole detection module, a drying module 8, a cleaning module 9, a tensioner, a rocker arm and a wire nozzle body 703, wherein the wire nozzle mechanism 7 is a part of the wire nozzle flaw detection module.

[0063] The fixed pulley block is the starting module for the enameled wire 2 on the winding machine body 1. The pinhole detection module, drying module 8 and cleaning module 9 are continuous functional modules and can be used as a complete functional component. The tensioner can be arranged before or after the above functional components. After the above modules, there is the swing rod, and then the wire mouth mechanism 7. Compared with the traditional winding machine, the pinhole detection module, drying module 8, cleaning module 9 and wire mouth flaw detection module are added.

[0064] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", and the like are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, features defined as "first", "second", and the like may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0065] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood by specific circumstances.

[0066] The above is based on the ideal embodiment of the present invention. Through the above description, relevant personnel can make various changes and modifications without departing from the technical concept of the present invention. The technical scope of the present invention is not limited to the content in the specification, and the technical scope must be determined according to the scope of the claims.

Claims

1. A winding machine, comprising a winding machine body (1), characterized in that: The winding machine body (1) is provided with a pinhole detection module and a wire nozzle flaw detection module, the pinhole detection module comprises a detection control module and a pinhole detection mechanism that cooperate with each other, the wire nozzle flaw detection module comprises a flaw detection control module and a wire nozzle mechanism (7) that cooperate with each other, and the enameled wire (2) passes through the pinhole detection mechanism and the wire nozzle mechanism (7) in sequence and is then wound around the iron core of the stator (10) to form a winding.

2. The winding machine according to claim 1, characterized in that: The pinhole detection mechanism comprises a container (501) for containing a conductive solution (508), the container (501) being fixedly mounted on the winding machine body (1), and two liquid-absorbing components (504) capable of opening and closing relative to each other are arranged inside the container (501); An electrode (507) is also provided at the bottom of the container (501), and the lower end of the liquid-absorbing component (504) and the electrode (507) are immersed in a conductive solution (508); The head end of the enameled wire (2) passes through between the two liquid-absorbing components (504), and the end of the enameled wire (2) is connected to the electrode (507) via a detection control module.

3. The winding machine according to claim 2, characterized in that: The detection control module comprises a detection power supply (401) and a voltage sampling circuit (403); one end of the detection power supply (401) is connected to the conductor (21) of the enameled wire (2), and the other end is connected to the electrode (507) via a first resistor (402); The electrode (507) forms a third resistor between the conductor (21) and the insulating layer (22) of the enameled wire (2) through the conductive solution (508); the voltage sampling circuit (403) is connected in parallel with the third resistor; and the voltage sampling circuit (403) is also connected in sequence to a voltage comparator (404), a timer (405) and a first counter (406).

4. The winding machine according to claim 1, characterized in that: The wire nozzle mechanism (7) comprises a sleeve (701) mounted on the winding machine body (1) and a wire nozzle body (703) in contact with the enameled wire (2), fixed pulleys (702) are provided at both ends of the sleeve (701), and the enameled wire (2) passes through the sleeve (701) and the wire nozzle body (703) in sequence and is then wound on the stator (10); The end of the enameled wire (2) and the nozzle body (703) are connected via a flaw detection control module.

5. The winding machine according to claim 4, characterized in that: The flaw detection control module comprises a flaw detection power supply (601), a second resistor (602), a diode, a current sampling circuit (603), a wire nozzle body (703) and an end of the enameled wire (2) which are sequentially connected in series, and the current sampling circuit (603) is also sequentially connected to an amplifier (604), a current comparator (605) and a second counter (606); The insulating layer (22) between the nozzle body (703) and the conductor (21) forms a fourth resistor, and when the insulating layer (22) is damaged, the conductor (21) is exposed and contacts the nozzle body (703).

6. The winding machine according to claim 1, characterized in that: The winding machine body (1) is also provided with a drying module (8) and a cleaning module (9), and the enameled wire (2) passes through the pinhole detection mechanism, the drying module (8) and the cleaning module (9) in sequence and then enters the wire nozzle mechanism (7).

7. The winding machine according to claim 6, characterized in that: The drying module (8) comprises a shell (801) connected to the winding machine body (1); the inner cavity of the shell (801) is divided into a blowing cavity (803), a heating cavity (804) and a cooling cavity (805) which are independent of each other by two partitions (802); and the enameled wire (2) passes through the blowing cavity (803), the heating cavity (804) and the cooling cavity (805) in sequence before entering the cleaning module (9).

8. The winding machine according to claim 7, characterized in that: The cleaning module (9) comprises two sets of take-up wheels (901) and driven wheels (902) arranged opposite to each other, a cleaning belt (903) being wound around the driven wheel (902), one end of the cleaning belt (903) passing around a tensioning wheel (904) and being wound around the take-up wheel (901), the enameled wire (2) passing between the two cleaning belts (903), and a clamping assembly for driving the cleaning belt (903) to contact the enameled wire (2) being arranged on one side of the tensioning wheel (904); The cleaning belt (903) continuously changes position under the drive of the tightening wheel (901), so as to always keep the clean surface in contact with the enameled wire (2).

9. A pinhole detection method, using the winding machine according to claim 3, characterized in that: The steps include: S1, collecting the voltage across the third resistor through a voltage sampling circuit (403), and inputting the voltage into a voltage comparator (404) for comparison with the voltage of a detection power supply (401); S2. If V1≤(U1×R0 / (R0+R1)), the timer (405) starts to work for a time of τ; wherein V1 is the voltage across the third resistor, U1 is the voltage of the detection power supply (401), R1 is the resistance value of the first resistor (402), and R0=10 kΩ; S3. If τ≥t, it is considered that a pinhole is found on the insulating layer (22) of the enameled wire (2), and the first counter (406) counts once; wherein t=5ms.

10. A wire nozzle flaw detection method, using the winding machine according to claim 5, characterized in that: The steps include: Step 1: The current flowing through the conductor (21) is collected through the current sampling circuit (603), and the amplified current signal is output through the amplifier (604), and then enters the current comparator (605) for comparison with the set current value; Step 2: If I1≥Iset, it is considered that the insulation layer (22) of the enameled wire (2) is damaged once, and the second counter (606) counts once; wherein I1 is the current signal output after being amplified by the amplifier (604), and Iset is the set current value.

Images