Winding machine and winding method thereof

Abstract

The invention discloses a winding machine and a winding method thereof. The winding machine comprises a rack, a false needle, a winding roller and a motor. The winding roller and the rack are rotationally installed, the motor is arranged on the rack, an output shaft of the motor is fixedly connected with a rotating shaft of the winding roller, and the motor rotates to drive the winding roller to rotate so as to conduct winding. One end of the winding roller is provided with a false needle, the false needle is used for fixing the free end of the copper wire, meanwhile, the device further comprises a spring buckle, and then tensioning in the copper wire winding process is achieved. At the same time, an angle formed by the copper wire and the wire, away from the false needle direction, of the central shaft of the winding roller is adjusted in the winding initial stage and the formal winding stage. Compared with the prior art, rapid and high-quality winding of the small Tesla coil is achieved through the spring buckle in the winding machine and adjustment of the angle formed by the copper wire and the wire, away from the direction of the false needle, of the center shaft of the winding roller.

Description

Technical Field

[0001] The invention belongs to the field of production and processing of inductor coils, in particular to a winding machine and a winding method thereof. Background Art

[0002] The small Tesla coil (usually refers to a Tesla coil with a secondary coil of 20mm diameter) is a wireless power transmission demonstration device used for scientific education (it can generate electric arcs, and some can also play music, or be used for commercial warm-up performances and magic, etc. Large Tesla coils are commonly seen in science and technology museums and other places). It is deeply loved by electronic enthusiasts or scientific educators. Many individual enthusiasts use hand drills and other hand tools to make the secondary coil of the Tesla coil. The production is difficult, and improper tension control may result in defects or even broken wires.

[0003] However, there is no winding machine for small Tesla coils at present. The professional winding equipment in the traditional winding industry occupies a large space and requires a large equipment investment. The production of such small Tesla coils is a waste of resources and requires a suitable fixture, which makes the investment large and uneconomical. The cost is very high. The present invention solves this dilemma and fills the gap in the market demand for a special winding machine for a small Tesla. Moreover, it has been verified by actual use that the production capacity is sufficient.

[0004] After the coil is wound, the traditional method is to wrap the coil by manually brushing insulating paint. This method has high requirements for the production personnel, and even if the coating is evenly applied, the insulating paint is not easy to dry (such as in rainy weather). At the same time, the cost of manually brushing insulating paint is high, the speed is slow, and it is not easy to mass produce. Summary of the invention

[0005] The object of the present invention is to provide a winding machine and a winding method thereof. The winding machine is a special device for producing a small Tesla secondary coil (single layer), thereby realizing the rapid production of a small Tesla secondary coil, improving the quality of the coil and reducing the cost.

[0006] The technical solution to achieve the purpose of the present invention is: a winding machine, including a frame, a dummy needle, a winding drum, and a motor; the winding drum is rotatably installed with the frame, the motor is arranged on the frame, the output shaft of the motor is fixedly connected to the rotating shaft of the winding drum, the motor rotates, driving the winding drum to rotate, and then winding is performed; a dummy needle is installed at one end of the winding drum, and the dummy needle is used to fix the free end of the copper wire.

[0007] Furthermore, the winding machine also includes a power module, a power socket, a switch, and an adjustable potentiometer with a switch; the power module, the power socket, the switch, and the adjustable potentiometer with a switch are all arranged on the frame, and the power module is used to adjust the power voltage to the required voltage to drive the motor to rotate; the power socket is the power supply access port; the switch is used to control the power on and off of the winding machine; the adjustable potentiometer with a switch is a speed control switch, which is used to send a signal to the power module and then adjust the driving voltage.

[0008] Furthermore, the winding machine also includes a spring buckle; the spring buckle provides appropriate tension for the copper wire so that the copper wire is appropriately tensioned and pulled out in an orderly manner.

[0009] Furthermore, the winding machine also includes a copper wire placement rack for placing the copper wire to be wound; the copper wire placement rack includes: a positioning frustum, a support plate, a cover body and a ceramic eyelet; the support plate is used to provide overall support for the copper wire placement rack; the positioning frustum is fixed on the support plate, and the positioning frustum is used to fix the copper wire spool; the lower edge of the cover body is just installed in the annular depression on the support plate, thereby covering the copper wire to be wound.

[0010] A winding method, applicable to the winding machine according to any one of claims 1 to 4, comprising the following specific steps:

[0011] S1, install the winding machine frame, spring buckle and copper wire placement rack;

[0012] S2: Place the entire spool of copper wire on the pallet, sort out the ends of the copper wire and pass them through the ceramic eyelets; the ends of the copper wire are inserted into the spring buckles fixed on the edge of the table;

[0013] S3: insert the wire tube onto the winding drum; make the wire tube close to the dummy needle end and clamp it in the concave part of the dummy needle;

[0014] S4: Wind the copper wire end along the winding drum around the thread above the false needle and fix it;

[0015] S5: winding;

[0016] At the beginning of the winding stage, rotate the winding drum, and the direction of rotation of the winding drum is away from the spring buckle; after the first circle, adjust the machine appropriately so that the second circle is close to the first circle;

[0017] In the formal winding stage, adjust the angle between the copper wire and the center axis of the winding drum away from the direction of the false needle;

[0018] S6: When the winding is almost full, turn down the potentiometer until it is closed to slow down the DC motor. If necessary, hold the shaft with your fingers and rub it so that the coil is fully wound when the winding drum stops.

[0019] S7: After the coil is fully wound, cut a wide polyimide tape to wrap the coil, cut the copper wire with a knife, and strip the wire ends at both ends of the small Tesla coil;

[0020] S9: Adjust the position of the winding machine, enter S3, insert a new wire tube, and start the next winding.

[0021] Further, in S4, when the copper wire end is fixed on the dummy needle along the winding drum, it is wound 2-3 times in a clockwise direction on a horizontal plane.

[0022] Furthermore, in S5, when winding begins, that is, before winding begins, the angle θ formed by the copper wire and the line in the direction away from the dummy needle by the center axis of the winding drum satisfies the angle requirement that: when the wire diameter is 0.13 mm, 88°<θ<90°.

[0023] Furthermore, in S5, during the formal winding, the angle θ formed by the copper wire and the line in the direction away from the dummy needle by the center axis of the winding drum meets the angle requirement that when the wire diameter is 0.13 mm, the angle range is 90°<θ<95°.

[0024] Furthermore, in S7, the ends of the wires at both ends of the small Tesla coil are stripped out by 2-3 cm.

[0025] Compared with the prior art, the present invention has the following significant advantages:

[0026] (1) The winding machine disclosed in the present invention has a simple structure, a compact size, a high winding efficiency, and a fast production speed, which promotes the small-batch production of small Tesla secondary coils.

[0027] (2) Use a dummy needle to quickly fix the free end of the wound copper wire.

[0028] (3) A spring buckle is used as a tensioner to provide appropriate tension for the orderly unwinding of the copper wire, thereby improving the quality of the wound coil. The wound coil is arranged tightly and beautifully, has strong practicality, and is extremely low in cost;

[0029] (4) At the beginning and during the winding process, the quality of the winding is improved by adjusting the angle between the copper wire and the central axis of the winding drum (away from the dummy needle). BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is the schematic diagram of the winding machine structure;

[0031] Figure 2 It is a schematic diagram of the internal structure of the winding machine;

[0032] Figure 3 It is a schematic diagram of the local structure of the winding drum and the wire tube;

[0033] Figure 4 It is a schematic diagram of the spring buckle structure;

[0034] Figure 5 It is a schematic diagram of the dust cover structure;

[0035] Figure 6 For fake needles;

[0036] Figure 7 Top view of the fake needle;

[0037] Figure 8 This is a diagram showing the positional relationship of the various components during winding operation. DETAILED DESCRIPTION

[0038] The following is combined with Figure 1-7 The present invention is further described with reference to the accompanying drawings and specific embodiments.

[0039] The present invention discloses a winding machine, comprising: a frame, a foot 1, an adjustable power module 2, a power socket 3, a switch 4, an adjustable potentiometer 6 with a switch, a dummy needle 10, a winding drum 11, a first bearing 13, a second bearing 14, a coupling 15, and a 550 DC motor 16.

[0040] The winding machine frame includes: an upper cover plate 31, a first baffle plate 5, a second baffle plate 7, a third baffle plate 8, a fourth baffle plate 9, a bottom plate 12 and a side plate 32; the first baffle plate 5, the second baffle plate 7, the third baffle plate 8, and the fourth baffle plate 9 are installed on the bottom plate 12 to form an overall frame of the winding machine frame.

[0041] like Figure 1 The four corners of the bottom of the winding machine frame are respectively provided with feet 1, and the adjustable power supply module 2 is installed on the bottom plate 12, which is used to adjust the power supply voltage to the required voltage to drive the 550 DC motor 16 to rotate; the power socket 3 is arranged on the first baffle 5, which is the power supply access port; the switch 4 is arranged on the first baffle 5, which is used to control the winding machine to turn on and off; the adjustable potentiometer 6 with switch is installed on the upper cover 31, which is a speed switch, used to send a signal to the adjustable power supply module 2 to adjust the driving voltage; the second baffle 7 is fixed with a 550 DC Motor 16; the third baffle 8 and the fourth baffle 9 are connected to the mounting shaft of the supporting winding drum 11 through the first bearing 13 and the second bearing 14; and the mounting shaft of the supporting winding drum 11 is connected to the output shaft of the 550 DC motor 16 through the coupling 15, so that the output shaft of the motor rotates, driving the supporting winding drum 11 to rotate; the supporting winding drum 11 is used to install the wire tube 33 of the small Tesla coil to be wound; the dummy needle 10 is installed at one end of the supporting winding drum 11, and is used to fix the thread end, that is, the free end of the copper wire.

[0042] like Figure 2As shown, a winding machine disclosed in the present invention also includes a spring buckle; the spring buckle provides appropriate tension for the copper wire so that the copper wire is appropriately tensioned and pulled out in an orderly manner; the spring buckle includes a buckle core 17 and a buckle body 24; the buckle core 17 is provided with a buckle core first hole 18 and a buckle core second hole 19, a spring positioning column head 21 is fixed on the buckle core 17, a spring 23 is fixed on the spring positioning column head 21, the other end of the spring 23 is fixed on the buckle body 24, and the buckle body 24 is provided with a buckle body first hole 20 and a buckle body second hole 22. When threading, the buckle core is appropriately pressed down to make the buckle body first hole transparent from top to bottom, that is, the buckle core first hole 18 and the buckle body first hole 20 form a through hole, and the copper wire is passed through the buckle body and the buckle core from bottom to top.

[0043] like Figure 3 As shown, a winding machine disclosed in the present invention also includes a copper wire placement rack for placing the copper wire to be wound; the copper wire placement rack includes: a positioning frustum 25, a support plate 26, a cover body 27 and a ceramic eyelet 28; the support plate 26 is used to provide overall support for the copper wire placement rack; the positioning frustum 25 is fixed on the support plate 26, and the positioning frustum 25 is used to fix the copper wire spool; the lower edge of the cover body 27 is just installed in the annular depression on the support plate 26, and the entire spool (the winding body of the copper wire material to be wound) and part of the support plate 26 can be covered (its lower edge just falls into the annular depression on the support plate 26), and the ceramic eyelet 28 is the outlet hole of the copper wire, which plays the role of axial unwinding guide yarn.

[0044] like Figure 6 As shown, the dummy needle 10 includes an upper threaded section 30, a middle section and a lower thread 29; the outer circle of the upper threaded section 30 is set as a conical thread surface, and the conical thread surface faces the side of the wire tube 33 (i.e., the winding body of the wound small Tesla coil, which is made of PVC), which is used to wind and fix the wire end of the wound copper wire; the dummy needle 10 is designed to be narrow at the top and wide at the bottom; the lower thread 29 of the dummy needle is used to be screwed onto the winding drum 11 for fixing.

[0045] The outer diameter of the winding drum 11 is slightly smaller than the inner diameter of the PVC pipe, so that the outer diameter has a certain adjustment space to adapt to the difference in the diameter of the PVC pipe, thereby providing sufficient friction to the PVC pipe and facilitating disassembly.

[0046] The present invention discloses a winding method for a winding machine: Here, a coil with a tube diameter of 20 mm, a wire diameter of 0.13 mm (outer diameter of 0.146), a tube length of 54, and a winding height of 50 mm is taken as an example:

[0047] like Figure 8 As shown, the winding machine, spring buckle and copper wire placement rack work together; the specific operation steps are:

[0048] S1, such as Figure 8 As shown in the figure, install the winding machine frame, spring buckle and copper wire placement rack;

[0049] S2: Put the whole shaft of copper wire (here, paint-free direct welding type polyurethane enameled wire with a wire diameter of 0.13mm) on the support plate 26, sort out the ends of the copper wire and pass them through the ceramic eyelet 28; the ends of the copper wire are inserted into the spring buckle fixed on the edge of the table;

[0050] S3: Insert the 54mm wire tube (tube diameter 20mm) onto the winding drum 11; if it is loose, use masking paper to wrap around the drum several times until it is adjusted so that the winding drum 11 provides sufficient friction to the wire tube 33 while being easy to disassemble; Figure 3 As shown, the wire tube is stuck in the concave part of the false needle 10 1-2 mm close to the false needle end (the thread 29 is fixed on the winding drum 11, and the thread 30 is outside);

[0051] S4: Wind the copper wire end along the winding drum 11 around the thread 30 above the dummy needle 10 for 2-3 turns and fix it (winding in a clockwise direction on a horizontal plane);

[0052] S5: Winding; rotating the winding drum 11, the winding drum 11 rotates in the direction away from the spring buckle; after the first circle, adjust the machine appropriately so that the second circle is close to the first circle,

[0053] During the winding stage, pay attention to adjusting the angle between the copper wire and the winding drum. That is, before winding, the angle θ formed by the copper wire and the central axis of the winding drum (away from the false needle) should be slightly less than 90 degrees on the left side (when the copper wire diameter is 0.13mm, 88°<θ<90°) to facilitate the start (i.e. the first 1-2 turns of winding);

[0054] At the same time, the distance between the winding machine and the operator needs to be adjusted, generally one arm's length is appropriate;

[0055] Formal winding stage: After winding the 1st or 2nd turns, adjust the angle θ formed by the copper wire and the central axis of the winding drum (away from the dummy needle) to be slightly larger than 90 degrees (when the copper wire diameter is 0.13mm, the angle range is 90°<θ<95°). Pay attention to maintaining this angle during the winding process. If the angle is too large, it will often cause winding overlap. If it is less than or equal to 90, the winding will be too loose, there will be gaps between the turns, and the arrangement will not be tight.

[0056] The adjustment of the above angles can be achieved by moving the winding machine frame.

[0057] S6: When the coil is almost fully wound (about 342 turns), adjust the potentiometer down until it is closed to slow down the DC motor. If necessary, you can grab the shaft with your fingers and rub it so that the coil is fully wound when the winding drum 11 stops (that is, the copper wire is 1-2mm away from the edge);

[0058] S7: After the coil is fully wound, cut a 65mm wide polyimide tape to wrap the coil, cut the 0.13 copper wire with a yarn cutter, and strip 2-3cm of the wire ends at both ends of the small Tesla coil.

[0059] You can manually cut 65mm wide polyimide tape to wrap the coil, use yarn scissors to cut the 0.13 copper wire, use wallpaper cutters to remove the excess parts at both ends, and strip 2-3cm of the wire ends of the small Tesla coil.

[0060] You can also use an automatic tape machine to cut a 65mm wide polyimide tape for wrapping, leaving 2-3cm when cutting the wire. Then trim the starting side, remove the 1-2 turns at the beginning, and leave 2-3cm of copper wire. In this way, a small Tesla coil is ready.

[0061] S9: Adjust the position of the winding machine, enter S3, insert a new wire tube 33, and start the next winding.

[0062] In the present invention, the winding machine and method can be used to conveniently and quickly produce a sufficient number of coils required. Taking a coil with a tube diameter of 20mm, a wire diameter of 0.13, a tube length of 54, and a winding height of 50mm as an example, the manual output per hour can reach 40-60, with a market value of 120-180. The present invention has the characteristics of low hardware overhead, fast winding speed, and beautiful molding.

[0063] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations on the present invention. A person skilled in the art may change, modify, replace and modify the above embodiments within the scope of the present invention without departing from the principles and intent of the present invention.

Claims

1. A winding machine, characterized in that: It includes a frame, a dummy needle, a winding drum, and a motor; the winding drum is rotatably installed with the frame, the motor is arranged on the frame, the output shaft of the motor is fixedly connected with the rotating shaft of the winding drum, the motor rotates, drives the winding drum to rotate, and then performs winding; a dummy needle is installed at one end of the winding drum, and the dummy needle is used to fix the free end of the copper wire.

2. The winding machine according to claim 1, characterized in that The winding machine also includes a power module, a power socket, a switch, and an adjustable potentiometer with a switch; the power module, the power socket, the switch, and the adjustable potentiometer with a switch are all arranged on the frame, the power module is used to adjust the power voltage to the required voltage to drive the motor to rotate; the power socket is the power supply access port; the switch is used to control the power on and off of the winding machine; the adjustable potentiometer with a switch is a speed control switch, which is used to send a signal to the power module and then adjust the driving voltage.

3. The winding machine according to claim 1, characterized in that The winding machine also includes a spring buckle; the spring buckle provides appropriate tension for the copper wire so that the copper wire is appropriately tensioned and drawn out in an orderly manner.

4. The winding machine according to claim 1, characterized in that The winding machine also includes a copper wire placement rack for placing the copper wire to be wound; the copper wire placement rack includes: a positioning round table, a support plate, a cover body and a ceramic buttonhole; the support plate is used to provide overall support for the copper wire placement rack; the positioning round table is fixed on the support plate, and the positioning round table is used to fix the copper wire spool; the lower edge of the cover body is just installed in the circular depression on the support plate, thereby covering the copper wire to be wound.

5. A winding method, characterized in that: Applicable to the winding machine described in any one of claims 1 to 4, the specific steps are: S1, install the winding machine frame, spring buckle and copper wire placement rack; S2: Place the entire spool of copper wire on the pallet, sort out the ends of the copper wire and pass them through the ceramic eyelets; the ends of the copper wire are inserted into the spring buckles fixed on the edge of the table; S3: insert the wire tube onto the winding drum; make the wire tube close to the dummy needle end and clamp it in the concave part of the dummy needle; S4: Wind the copper wire end along the winding drum around the thread above the false needle and fix it; S5: winding; At the beginning of the winding stage, rotate the winding drum, and the direction of rotation of the winding drum is away from the spring buckle; after the first circle, adjust the machine appropriately so that the second circle is close to the first circle; In the formal winding stage, adjust the angle between the copper wire and the center axis of the winding drum away from the direction of the false needle; S6: When the winding is almost full, turn down the potentiometer until it is closed to slow down the DC motor. If necessary, hold the shaft with your fingers and rub it so that the coil is fully wound when the winding drum stops. S7: After the coil is fully wound, cut a wide polyimide tape to wrap the coil, cut the copper wire with a knife, and strip the wire ends at both ends of the small Tesla coil; S9: Adjust the position of the winding machine, enter S3, insert a new wire tube, and start the next winding.

6. A winding method according to claim 5, characterized in that: In S4, when the copper wire end is fixed on the dummy needle along the winding drum, it is wound 2-3 times in the clockwise direction on the horizontal plane.

7. A winding method according to claim 6, characterized in that: In S5, when winding begins, that is, before winding begins, the angle θ formed by the copper wire and the line of the center axis of the winding drum away from the direction of the dummy needle meets the angle requirement that: when the diameter of the copper wire is 0.13 mm, 88°<θ<90°.

8. A winding method according to claim 5, characterized in that: In S5, during the formal winding, the angle θ formed by the copper wire and the line away from the dummy needle direction by the center axis of the winding drum meets the angle requirement: when the copper wire diameter is 0.13 mm, the angle range is 90°<θ<95°.

9. A winding method according to claim 5, characterized in that: In S7, strip 2-3cm of wire ends from both ends of the small Tesla coil.

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