Winding method and device for coil with small wire diameter and small inner diameter

Abstract

The invention discloses a winding method and device for a coil with a small wire diameter and a small inner diameter. The method comprises the following steps: S1, determining various parameters of a wound coil, and selecting a proper winding shaft and a proper coil framework; s2, adjusting an adjusting knob of each module; s3, the winding shaft is inserted into the coil framework, and the winding shaft and the coil framework are fixed; s4, enabling the enameled wire to pass through the winding displacement pipe, and then fixing the enameled wire on the coil framework; s5, resetting the wire arranging device; s6, setting the parameters in the S1; s7, the machine is started, the rotating main shaft does rotating motion, the wire arranging shaft does axial translation motion, and a layer is wound; s8, brushing a layer of metal glue on the wound layer of coil; s9, judging whether the number of turns of the wound coils is sufficient or not, if not, repeating the steps S7 and S8, and if yes, completing winding; and S10, after winding is completed, the coil framework and the coil are taken down. The device comprises a base, a wire arranging mechanism, a rotating mechanism and a framework platform mechanism. The method and the device can be used for directly producing the coil according to each parameter and manufacturing the high-precision coil, so that the coil can continuously operate for a long time.

Description

Technical Field

[0001] The invention relates to the technical field of industrial machinery production, and in particular to a method and a device for winding a coil with a thin wire diameter and a small inner diameter. Background Art

[0002] Winding machines are one of the most important products in mechanical production all over the world. Many devices that require winding are inseparable from winding machines, and coils are important components in the production of many electronic products such as transformers, mutual inductors, inductors, detectors, etc.

[0003] With the leap in the technological level of electronic equipment, the size of electronic equipment is pursued to be miniaturized and lightweight, and the requirements for coils are gradually increasing. The performance structure of the current conventional winding machine cannot meet the requirements of small coil diameter and small wire diameter. This type of small inner diameter enameled wire coil is mainly wound by hand.

[0004] When the inner diameter of the coil wound by the existing winding machine is too small, the main shaft, i.e. the winding shaft, will become unstable, resulting in problems such as the inability to arrange the wires neatly, the enameled wire breaking due to poor tension control when winding the coils, and personal injuries caused by machine damage.

[0005] Chinese invention patent CN108492976A provides a method for preparing a coil, but it is made by a stamping process, which causes the copper wire to deform during the stamping process, causing the coil resistance to change, and it is impossible to make a high-precision coil. Chinese invention patent CN110444390A provides a method for setting a wire reel to reduce the tension generated during the winding process. The provided coil winding method solves the problem of changing the thickness of the copper wire due to tension during the coil winding process, but does not provide a method for direct production by setting the coil width, coil inner diameter, number of turns per layer of winding and total number of turns, as well as a method for dealing with the bending of the shaft caused by long-term operation. Chinese invention patent CN102867644A provides an automatic winding equipment for inductor coils. The provided device can wind various coils with different inner and outer diameters on demand, but also does not provide a method for direct production by setting the coil width, coil inner diameter, number of turns per layer of winding and total number of turns, as well as a method for dealing with the bending of the shaft caused by long-term operation. Chinese invention patent CN113963940A provides a hollow inductor coil production and manufacturing device, which solves the problem of insufficient uniformity of the current winding device, but ignores the problem of tension changing the thickness of the copper wire during the winding process, and the problem of bending of the shaft after long-term operation. In summary, the existing coil winding equipment is not conducive to the production of high-precision coils, and is not conducive to long-term continuous operation. It is impossible to directly produce coils according to the required coil width, coil inner diameter, number of turns per layer of winding, and total number of turns.

[0006] Therefore, it is necessary for those skilled in the art to provide a method and device for winding a thin-wire and small-inner-diameter coil to solve the above-mentioned technical problems. Summary of the invention

[0007] The present invention provides a method and device for winding a coil with a thin wire diameter and a small inner diameter, which solves the problems that the coil cannot be directly produced according to the required coil width, coil inner diameter, number of turns per layer of winding and total number of turns, high-precision coils cannot be manufactured, and the coil is not convenient for long-term continuous operation.

[0008] In order to solve the above technical problems, the present invention provides a method and device for winding a thin wire and small inner diameter coil, comprising the following steps:

[0009] A method for winding a thin wire diameter and small inner diameter coil comprises the following steps:

[0010] S1. Determine the coil width, coil inner diameter, number of turns per layer and total number of turns of the winding coil, and select a suitable winding shaft and coil frame;

[0011] S2. Adjust the adjustment knobs of each module of the fixed coil frame platform;

[0012] S3, insert the winding shaft into the coil frame, insert one end of the winding shaft into the shaft support, then slide the slider to put the other end of the winding shaft into the three-jaw chuck, tighten the three-jaw chuck, and fix the winding shaft and the coil frame;

[0013] S4, pass the enameled wire through the wire tube, then through the pre-tightening device and out through the guide needle, and then fix it on the coil frame;

[0014] S5, then reset the cable arrangement device;

[0015] S6. Set the diameter of the enameled wire, coil width, coil inner diameter, number of turns per layer and total number of turns;

[0016] S7. After setting, start the machine, rotate the main shaft to make a rotational motion, and the wire arrangement shaft to make an axial translational motion, and the two cooperate to make the enameled wire wind one layer in a spiral path;

[0017] S8. Apply a thin layer of metal glue evenly on the wound coil and let it cool for one minute;

[0018] S9, judging whether the number of coil turns is sufficient, if not, repeating steps S7 and S8, if sufficient, the winding is completed;

[0019] S10. Wait for the winding to be completed, release the three-jaw chuck, move the slider and the shaft to the rightmost end, and remove the coil frame and the coil.

[0020] A winding device for a thin-wire and small-inner-diameter coil, comprising:

[0021] A base that provides stability and load-bearing function;

[0022] A wire arrangement mechanism, the wire arrangement mechanism comprises a mounting bracket, a driving motor, a belt transmission device, a screw rod, a threaded slider, a wire arrangement shaft, a wire arrangement tube, a pre-tightening device and an adjusting steering gear, the mounting bracket is fixedly mounted on the base, the mounting bracket is mounted with a driving motor, the shaft end of the driving motor is connected with a screw rod through a belt transmission device, the screw rod is rotatably mounted on the mounting bracket, a threaded slider is threadedly mounted on the screw rod, a wire arrangement shaft is fixedly mounted on the threaded slider, the wire arrangement shaft passes through the mounting bracket, the wire arrangement shaft is slidably mounted between the mounting bracket and the base, the wire arrangement tube and the pre-tightening device are both mounted on the wire arrangement shaft, and the adjusting steering gear is mounted on the connecting rod of the pre-tightening device;

[0023] A rotating mechanism, the rotating mechanism comprising a rotating motor, a spindle and a three-jaw chuck, the rotating motor being fixedly mounted on the base, the shaft end of the rotating motor passing through the base, the spindle being fixedly mounted on the shaft end of the rotating motor, and the three-jaw chuck being fixedly mounted on the spindle;

[0024] A skeleton platform mechanism, the skeleton platform mechanism includes a y-axis adjustment knob, an x-axis adjustment knob, an x-axis adjustment module, a y-axis adjustment module, a screw transmission block, a fastening block one, a fastening block two and a screw, the y-axis adjustment module is vertically fixedly installed on the screw transmission block, clamped by the fastening block one and the fastening block two, and then installed by bolt connection, the x-axis adjustment module is horizontally installed on the y-axis adjustment module by bolts, and at the same time, there is a hole in the center of the x-axis adjustment module for fixing the winding shaft, and the above-mentioned hole and the three-jaw chuck together fix the winding shaft and the skeleton.

[0025] Preferably, the belt transmission device includes a first pulley, a belt and a second pulley, the first pulley is fixedly mounted on the shaft end of the drive motor, the belt connects the first pulley and the second pulley, and the second pulley is fixedly mounted on one end of the screw rod.

[0026] Preferably, the supporting part of the cable duct is composed of a fixed rod, a connecting spring, a movable rod and a connecting cover. The fixed rod is fixedly mounted on the cable duct shaft, the connecting spring connects the fixed rod and the movable rod, a connecting cover is fixedly mounted on the movable rod, and the connecting cover is movably mounted on the fixed rod.

[0027] Preferably, a fixing plate is fixedly mounted on the fixing rod, a telescopic member is mounted on the fixing plate, a contact switch is fixedly mounted on the shaft end of the telescopic member, the contact switch is adapted to the connecting cover, and an output end of the contact switch is electrically connected to a control end of the rotating motor.

[0028] Preferably, it also includes a camera module for photographing the winding shaft and two electromagnet modules used in conjunction with the camera module. The camera module is installed on the x-axis adjustment module, facing the winding shaft, and the two electromagnet modules are located below and to the side of the tungsten steel shaft.

[0029] Preferably, it also includes a tension sensor for monitoring the tension of the wound copper wire and an active wire feeding mechanism for conveying the wound copper wire. The tension sensor is installed horizontally below the wire traversing tube, and the active wire feeding mechanism is installed horizontally directly below the wire traversing tube.

[0030] Preferably, the threaded surface of the screw rod is located within the range of the mounting bracket; the wire arrangement shaft is distributed parallel to the screw rod, and the wire arrangement shaft is a stainless steel structure.

[0031] Preferably, the cable traversing tube is installed above the cable traversing shaft, and the pre-tightening device is installed below the cable traversing shaft; the main shaft matches the shaft support.

[0032] Preferably, the fixed rod and the movable rod have the same size, and the fixed rod and the movable rod are spaced 50 mm apart.

[0033] Compared with the related art, the winding method and device of the thin wire diameter and small inner diameter coil provided by the present invention have the following beneficial effects:

[0034] The present invention provides a method and device for winding a coil with a thin wire diameter and a small inner diameter. By selecting a suitable winding shaft and a coil frame, coils of different specifications can be wound by selecting different winding shafts and coil frames. Compared with the existing winding machines, the present invention has stronger adaptability.

[0035] Adjust the skeleton platform to ensure that during the winding process, the axis of the three-jaw chuck coincides with the axis of the hole on the shaft support that matches the winding shaft, and then reset the wire arrangement device to ensure that the guide pin hole is aligned with the edge of the coil skeleton. This operation can reduce the possibility of copper wire winding and knotting during the winding process; setting the coil width, coil inner diameter, number of turns per layer and total number of turns is more convenient than the existing winding; at the beginning of winding, while winding, brushing glue can ensure that the wound coil is firm and not easy to deform; aligning the guide pin hole with the edge of the coil skeleton and the wire outlet is tangent to the coil, which can reduce the winding process. The problem of copper wire entanglement in the wire winding process; the tension sensor is linked to the active wire feeding mechanism; when the tension reaches the set threshold, the active wire feeding device will accelerate the wire feeding, thereby reducing the tension of the copper wire; this process ensures that the thickness of the copper wire in each part of the coil is equivalent and the resistance is almost consistent, thereby achieving a high-precision effect; the camera module is linked to the electromagnet module, and the camera module is facing the winding shaft. When the winding shaft is subjected to the tension from the copper wire and produces deformation, the two electromagnets begin to work and generate attraction on the shaft, thereby offsetting the tension of the copper wire and preventing the shaft from deforming after working for a long time, which affects the coil winding accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 A flow chart of a method for winding a thin-wire and small-inner-diameter coil provided by the present invention;

[0037] Figure 2 A schematic structural diagram of a first embodiment of a winding device for a thin-wire and small-inner-diameter coil provided by the present invention;

[0038] Figure 3 for Figure 2 A schematic diagram of the structure of the wiring mechanism part;

[0039] Figure 4 for Figure 2 A schematic diagram of the structure of the rotating mechanism part;

[0040] Figure 5 for Figure 2 A three-dimensional diagram of the skeleton platform mechanism part;

[0041] Figure 6 for Figure 2 A schematic diagram of the structure of the belt transmission device part;

[0042] Figure 7 A schematic structural diagram of a second embodiment of a winding device for a thin-wire and small-inner-diameter coil provided by the present invention;

[0043] Figure 8 for Figure 7 The enlarged schematic diagram of the middle A part;

[0044] Fig. 9 An axonometric view of a winding device for a thin-wire, small-inner-diameter coil;

[0045] Fig.10 It is a rear view of the winding device for a thin wire and small inner diameter coil;

[0046] Fig.11 Schematic diagram of the electromagnet module offsetting the tension of the copper wire.

[0047] Numbers in the figure:

[0048] 1. Base;

[0049] 2. Wire arrangement mechanism; 21. Mounting bracket; 22. Driving motor; 23. Belt transmission device; 231. First pulley; 232. Belt; 233. Second pulley; 24. Screw rod; 25. Threaded slider; 26. Wire arrangement shaft; 27. Wire arrangement tube; 271. Fixed rod; 272. Connecting spring; 273. Movable rod; 274. Connecting cover; 28. Preload device; 29. ​​Adjusting servo; 210. Guide pin

[0050] 3. Rotating mechanism; 31. Rotating motor; 32. Spindle; 33. Three-jaw chuck;

[0051] 4. Skeleton platform mechanism; 41. Y-axis adjustment knob; 42. X-axis adjustment knob; 43. X-axis adjustment module; 44. Y-axis adjustment module; 45. Lead screw transmission block; 46. Fastening block one; 47. Fastening block two; 48. Lead screw;

[0052] 5. Fixed plate;

[0053] 6. Telescopic parts;

[0054] 7. Contact switch;

[0055] 8. Camera module;

[0056] 9. Tension sensor;

[0057] 10. Electromagnet module;

[0058] 11. Active wire feeding mechanism; 111. Coil; 112. Wire feeding servo. DETAILED DESCRIPTION

[0059] The present invention will be further described below in conjunction with the accompanying drawings and implementation modes.

[0060] See also Figure 1 The present invention provides a method and device for winding a thin-wire and small-inner-diameter coil, comprising the following steps:

[0061] S1. Determine the coil width, coil inner diameter, number of turns per layer and total number of turns of the winding coil, and select a suitable winding shaft and coil frame;

[0062] S2. Adjust the adjustment knobs of each module of the fixed coil frame platform;

[0063] S3, insert the winding shaft into the coil frame, insert one end of the winding shaft into the shaft support, then slide the slider to put the other end of the winding shaft into the three-jaw chuck, tighten the three-jaw chuck, and fix the winding shaft and the coil frame;

[0064] S4, pass the enameled wire through the wire tube, then through the pre-tightening device and out through the guide needle, and then fix it on the coil frame;

[0065] S5, then reset the cable arrangement device;

[0066] S6. Set the diameter of the enameled wire, coil width, coil inner diameter, number of turns per layer and total number of turns;

[0067] S7. After setting, start the machine, rotate the main shaft to make a rotational motion, and the wire arrangement shaft to make an axial translational motion, and the two cooperate to make the enameled wire wind one layer in a spiral path;

[0068] S8. Apply a thin layer of metal glue evenly on the wound coil and let it cool for one minute;

[0069] S9, judging whether the number of coil turns is sufficient, if not, repeating steps S7 and S8, if sufficient, the winding is completed;

[0070] S10. Wait for the winding to be completed, release the three-jaw chuck, move the slider and the shaft to the rightmost end, and remove the coil frame and the coil.

[0071] Compared with the related art, the winding method and device of the thin wire diameter and small inner diameter coil provided by the present invention have the following beneficial effects:

[0072] Select a suitable winding shaft and coil frame to ensure that the winding shaft does not deform during the winding process, ensure that the axis of the three-jaw chuck coincides with the axis of the hole on the shaft support that matches the winding shaft, and then reset the wire arrangement mechanism to ensure that the guide pin hole is aligned with the edge of the coil frame and the wire outlet is tangent to the coil, which can reduce the problem of copper wire entanglement during the winding process.

[0073] See also Figure 2-Figure 6 The present invention also provides a winding device for a thin-wire and small-inner-diameter coil, comprising:

[0074] A base 1 for stability and bearing;

[0075] A wire arrangement mechanism 2, the wire arrangement mechanism 2 comprises a mounting bracket 21, a driving motor 22, a belt transmission device 23, a screw 24, a threaded slider 25, a wire arrangement shaft 26, a wire arrangement tube 27, a pre-tightening device 28 and an adjusting steering gear 29, the mounting bracket 21 is fixedly mounted on the base 1, the mounting bracket 21 is mounted with a driving motor 22, the shaft end of the driving motor 22 is connected with a screw 24 through a belt transmission device 23, the screw 24 is rotatably mounted on the mounting bracket 21, a threaded slider 25 is threadedly mounted on the screw 24, a wire arrangement shaft 26 is fixedly mounted on the threaded slider 25, the wire arrangement shaft 26 passes through the mounting bracket 21, the wire arrangement shaft 26 is slidably mounted between the mounting bracket 21 and the base 1, the wire arrangement tube 27 and the pre-tightening device 28 are both mounted on the wire arrangement shaft 26, and the adjusting steering gear 29 is mounted on the connecting rod of the pre-tightening device 28;

[0076] The rotating mechanism 3 includes a rotating motor 31, a spindle 32 and a three-jaw chuck 33. The rotating motor 31 is fixedly mounted on the base 1. The shaft end of the rotating motor 31 passes through the base 1. The spindle 32 is fixedly mounted on the shaft end of the rotating motor 31. The three-jaw chuck 33 is fixedly mounted on the spindle 32.

[0077] The skeleton platform mechanism 4 includes a y-axis adjustment knob 41, an x-axis adjustment knob 42, an x-axis adjustment module 43, a y-axis adjustment module 44, a screw transmission block 45, a fastening block one 46, a fastening block two 47 and a screw 48. The y-axis adjustment module 44 is vertically fixedly installed on the screw transmission block 45, clamped by the fastening block one 46 and the fastening block two 47, and then installed by bolt connection. The x-axis adjustment module 43 is horizontally installed on the y-axis adjustment module 44 by bolts. At the same time, there is a hole in the center of the x-axis adjustment module 43 for fixing the winding shaft. The above-mentioned hole and the three-jaw chuck 33 fix the winding shaft and the skeleton together.

[0078] The emergency stop mechanism is composed of a fixed plate 5, a telescopic member 6, and a contact switch 7.

[0079] The emergency stop mechanism is connected to the lower part of the cable tube 27 by bolts through a fixing plate 5, and a telescopic member 6 and a contact switch 7 are installed on the fixing plate. When the speed is too fast, the connecting spring 272 is tightened, triggering the contact switch 7, and the device stops running. Figure 2 shown.

[0080] It also includes a camera module 8 for photographing the winding shaft, a tension sensor 9 for monitoring the tension of the wound copper wire, an active wire feeding mechanism 11 for conveying the wound copper wire, and two electromagnet modules 10 used in conjunction with the camera module 8. The camera module 8 is installed on the x-axis adjustment module 43, facing the winding shaft. At the same time, the camera module 8 cooperates with the electromagnet module 10. When the winding shaft bends and deforms under the long-term tension of the copper wire, the camera module detects the shape change, and the two electromagnet modules 10 adjust the magnetic force according to the image data processed by the camera module to offset the tension of the copper wire and restore the winding shaft to normal.

[0081] As attached Figure 2 As shown, the tension sensor 9 is horizontally installed below the wire arranging tube 27, and the active wire feeding mechanism 11 is horizontally installed directly below the wire arranging tube 27. The tension sensor 9 cooperates with the wire feeding servo 112. When the value measured by the tension sensor 9 reaches a set threshold, the wire feeding servo 112 accelerates the rotation of the wire feeding to reduce the tension on the copper wire and prevent the copper wire from being deformed.

[0082] The tail of the pre-tightening device 28 has an arc-shaped groove, which can be installed with a guide needle 210, so that copper wires with smaller wire diameters can be transported and the accuracy and stability of wire transmission can be ensured.

[0083] The wire arrangement tube 27 and the pre-tightening device 28 are fixedly connected to the wire arrangement shaft 26 and follow the wire arrangement shaft 26 to make axial translation. The arc-shaped groove at the tail of the pre-tightening device 28 is convenient for installing the guide needle 210, and can also convey fine wires, and ensure the accuracy and stability of the wire transmission, realize step-by-step force application, and make the force on the wire more uniform. The three-jaw chuck 33 is fixedly connected to the main shaft 32 and follows the main shaft 32 to make rotational movement, which is used to fix the winding shaft and the skeleton and drive them to rotate. The skeleton platform mechanism 4 and the three-jaw chuck 33 fix the winding shaft and the skeleton together. The screw transmission block 45 is fixed on the screw 48 and can move left and right. The left and right movement of the skeleton platform mechanism 4 is used to ensure the stability when winding different coils. When winding a coil with a small inner diameter, the length of the winding shaft can be shortened to ensure its rigidity.

[0084] The driving motor 22 is a stepping motor, which is connected to an external power source when in use, and provides a power source for the rotation adjustment of the screw rod 24;

[0085] When the screw rod 24 rotates forward, the threaded slider 25 drives the cable shaft 26 to move forward horizontally;

[0086] When the screw rod 24 is reversed, the threaded slider 25 drives the cable arrangement shaft 26 to move backward laterally, so as to adjust the use point of the cable arrangement shaft 26.

[0087] The rotating motor 31 is a brushless DC motor, which is connected to an external power source when in use to provide a power source for the rotation adjustment of the three-jaw chuck 33 .

[0088] The belt transmission device 23 includes a first pulley 231, a belt 232 and a second pulley 233. The first pulley 231 is fixedly mounted on the shaft end of the driving motor 22. The belt 232 connects the first pulley 231 and the second pulley 233. The second pulley 233 is fixedly mounted on one end of the screw rod 24.

[0089] The belt transmission device 23 is used to connect the driving motor 22 and the screw rod 24, and provides a stable power source for the rotation adjustment of the screw rod 24;

[0090] In an optional manner, the belt drive device 23 can be replaced by a sprocket drive structure according to usage requirements.

[0091] The threaded surface of the screw rod 24 is located within the range of the mounting bracket 21 .

[0092] When the screw rod 24 rotates, the threaded slider 25 can be moved and adjusted within the range of the mounting bracket 21 .

[0093] The wire arrangement shaft 26 is arranged parallel to the screw rod 24 , and the wire arrangement shaft 26 is a stainless steel structure.

[0094] The cable traversing tube 27 is installed above the cable traversing shaft 26 , and the pre-tightening device 28 is installed below the cable traversing shaft 26 .

[0095] The main shaft 32 is installed on the outside of the base 1 , and the main shaft 32 matches the shaft support 45 .

[0096] The working principle of the winding device for the thin wire diameter and small inner diameter coil provided by the present invention is as follows:

[0097] S1 Determine the coil width, coil inner diameter, number of turns per layer and total number of turns of the winding coil, select the appropriate winding shaft and coil frame and tungsten steel shafts of different specifications;

[0098] S2 adjusts the adjustment knobs of each module of the fixed coil frame platform;

[0099] S3 inserts the winding shaft into the coil frame, inserts one end of the winding shaft into the shaft support 45, then slides the slider 44 to put the other end of the winding shaft into the three-jaw chuck 33, tightens the three-jaw chuck 33, and fixes the winding shaft and the coil frame;

[0100] S4 passes the enameled wire through the wire arranging tube 27, then through the pre-tightening device 28 and out through the guide needle, and then fixed on the coil frame;

[0101] S5 then resets the wire arrangement mechanism 2; when resetting the wire arrangement mechanism 2, the inner diameter of the winding coil is input, and the adjustment servo 29 will adjust the inclination angle of the wire arrangement mechanism 2 according to the inner diameter until the wire outlet is tangent to the coil frame, making the winding process smoother.

[0102] S6 sets the diameter of the enameled wire, coil width, coil inner diameter, number of turns per layer and total number of turns;

[0103] After S7 is set up, the machine is started, the main shaft 32 rotates, and the wire arrangement shaft 26 moves axially. The two cooperate to wind the enameled wire in a spiral path. During the winding process, the tungsten steel shaft is prone to bending due to the long-term tension of the copper wire. We installed two electromagnet modules 10 in the horizontal and vertical directions of the tungsten steel shaft. The two electromagnet modules 10 work together to offset the tension of the copper wire on the tungsten steel shaft. At the same time, when the camera module 8 facing the shaft detects that the shaft has been bent, the electromagnet module 10 will adjust the magnetic force and the direction of the resultant force according to the degree of bending and the angle of the servo 29 to adjust the tungsten steel shaft to a normal state.

[0104] S8: Apply a thin layer of metal glue evenly on the wound coil and let it cool for one minute;

[0105] S9 determines whether the number of turns of the wound coil is sufficient. If not, repeat steps S7 and S8. If sufficient, the winding is completed.

[0106] S10: Wait until the winding is completed, release the three-jaw chuck 33, move the slider 44 and the shaft to the rightmost end, and remove the coil frame and the coil.

[0107] The beneficial effects of the winding device for a thin wire diameter and small inner diameter coil provided by the present invention are as follows:

[0108] The wire arrangement tube 27 and the pre-tightening device 28 are fixedly connected to the wire arrangement shaft 26 and follow the wire arrangement shaft 26 to make axial translation. The arc-shaped groove at the tail of the pre-tightening device 28 is convenient for installing the guide needle, and can also convey small wires, and ensure the accuracy and stability of the wire transmission, realize step-by-step force application, and make the force on the wire more uniform. The three-jaw chuck 33 is fixedly connected to the main shaft 32 and follows the main shaft 32 to make rotational movement, which is used to fix the winding shaft and the skeleton and drive them to rotate. The shaft support 45 and the three-jaw chuck 33 fix the winding shaft and the skeleton together. The slider 44 is fixed between the two guide rails 41 and can move left and right. The left and right movement of the skeleton platform 4 is used to ensure its stability when winding different coil widths. When winding a coil with a small inner diameter, the length of the winding shaft can be shortened to ensure its rigidity.

[0109] For further information, see Figure 7-Figure 8 The supporting part of the cable tube 27 is composed of a fixed rod 271, a connecting spring 272, a movable rod 273 and a connecting cover 274. The fixed rod 271 is fixedly installed on the cable shaft 26. The connecting spring 272 connects the fixed rod 271 and the movable rod 273. A connecting cover 274 is fixedly installed on the movable rod 273. The connecting cover 274 is movably installed on the fixed rod 271. A fixed plate 5 is fixedly installed on the fixed rod 271. A telescopic member 6 is installed on the fixed plate 5. A contact switch 7 is fixedly installed on the shaft end of the telescopic member 6. The contact switch 7 is adapted to the connecting cover 274. The output end of the contact switch 7 is electrically connected to the control end of the rotating motor 31.

[0110] The wire arranging part of the wire arranging tube 27 is movably mounted on the fixed rod 271 through the movable rod 273, so that when the thin wire is subjected to a sudden increase in traction force during the winding process, it can provide stable buffer protection. At the same time, when the movable rod 273 drives the connecting cover 284 to move downward and abuts against the contact switch 7, the rotating motor 31 is turned off, thereby achieving a safe closure during winding traction and avoiding the phenomenon of wire breakage due to excessive tension when the thin wire is pulled.

[0111] At the same time, in order to prevent the copper wire from being subjected to excessive tension during the winding process, thereby causing deformation and uneven coil resistance, a tension sensor 9 and an active wire feeding mechanism 11 are installed under the wire tube 27. The two work together to achieve the effect of reducing tension, taking a copper wire with a diameter of 0.5 mm as an example.

[0112] The Young's modulus of copper is about 110 GPa, and its cross-sectional area A is about A = π × (0.0005 / 2) 2 ≈

[0113] 1.9635×10 -7 m 2 The stress σ can be expressed as σ = F / A, where F is the applied force.

[0114] Stress σ can be expressed as σ=E×∈, where E is Young's modulus (tensile modulus) and ∈ is strain.

[0115] Assuming we want the copper wire to not deform beyond its elastic limit (usually 0.2% of the material strain), we can set the strain to 0.002.

[0116] From this the required stress can be calculated:

[0117] σ=E×∈=110×10 9 ×0.002=2.2×10 8 Pa;

[0118] Then calculate the applied force:

[0119] F = σ × A = 2.2 × 10 8 ×1.9635×10 -7 ≈43.20N.

[0120] Therefore, a copper wire with a diameter of 0.5 mm will produce a measurable deformation when a tension of about 43.20 N is applied. We set that when the tension value measured by the tension sensor 9 is greater than 35 N, the active wire feeding servo 112 accelerates the wire feeding until the tension is reduced to 20 N and stops accelerating. This achieves the effect of preventing the copper wire from deforming.

[0121] During the winding process, as the coil increases layer by layer, the outlet is at an angle a to the horizontal direction. Adjusting the steering gear 29 will adaptively change a to ensure that the outlet can always be tangent to the coil boundary. Fig.11 shown.

[0122] The attraction generated by the transverse electromagnet is Fx, and the attraction generated by the longitudinal electromagnet is Fy, and their magnitude ratio is This will offset the tension of the copper wire on the tungsten steel shaft. Fig.11 shown.

[0123] The fixed rod 271 and the movable rod 273 have the same size, and the fixed rod 271 and the movable rod 273 are spaced 50 mm apart.

[0124] The connection cover 274 is a plastic structure, and the thickness of the connection cover 274 is 5 mm.

[0125] The connecting cover 274 is fixed on the movable rod 273 , sleeved on the fixed rod 271 , and can be slidably adjusted on the fixed rod 271 .

[0126] The connecting spring 272 is installed in the connecting cover 274 and is used to connect the fixed rod 271 and the movable rod 273 .

[0127] The telescopic member 6 is an electric telescopic rod, which is connected to an external power source when in use, and provides a power source for the telescopic adjustment of the contact switch 7;

[0128] When the contact switch 7 is retracted, it is in a non-use state and does not contact the connection cover 274;

[0129] When the contact switch 7 is unfolded, it is in use state, is located within the movable range of the connection cover 274, and can come into contact with the connection cover 274.

[0130] The working principle of the second embodiment of the winding device for a thin-wire and small-inner-diameter coil provided by the present invention is as follows:

[0131] During the winding process, the thin wire is subjected to traction. If the traction increases, the relative pulling force on the cable duct 27 increases, and the cable duct 27 drives the movable rod 273 and the connecting cover 274 to shrink on the fixed rod 271.

[0132] When the surface of the fixing rod 271 contacts the contact switch 7 in the on state, the rotating motor 31 can be closed adaptively to prevent the thin wire from being broken due to excessive tension.

[0133] The beneficial effects of the winding device for a thin-wire and small-inner-diameter coil provided by the present invention;

[0134] The wire arranging part of the wire arranging tube 27 is movably mounted on the fixed rod 271 through the movable rod 273, so that when the thin wire is subjected to a sudden increase in traction force during the winding process, it can provide stable buffer protection. At the same time, when the movable rod 273 drives the connecting cover 284 to move downward and abuts against the contact switch 7, the rotating motor 31 is turned off, thereby achieving a safe closure during winding traction and avoiding the phenomenon of wire breakage due to excessive tension when the thin wire is pulled.

[0135] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A method for winding a thin wire and small inner diameter coil, characterized in that: The following steps are involved: S1. Determine the coil width, coil inner diameter, number of turns per layer and total number of turns of the winding coil, and select a suitable winding shaft and coil frame; S2. Adjust the adjustment knobs of each module of the fixed coil frame platform; S3, insert the winding shaft into the coil frame, insert one end of the winding shaft into the shaft support, then slide the slider to put the other end of the winding shaft into the three-jaw chuck, tighten the three-jaw chuck, and fix the winding shaft and the coil frame; S4, pass the enameled wire through the wire tube, then through the pre-tightening device and out through the guide needle, and then fix it on the coil frame; S5, then reset the cable arrangement device; S6. Set the diameter of the enameled wire, coil width, coil inner diameter, number of turns per layer and total number of turns; S7. After setting, start the machine, rotate the main shaft to make a rotational motion, and the wire arrangement shaft to make an axial translational motion, and the two cooperate to make the enameled wire wind one layer in a spiral path; S8. Apply a thin layer of metal glue evenly on the wound coil and let it cool for one minute; S9, judging whether the number of coil turns is sufficient, if not, repeating steps S7 and S8, if sufficient, the winding is completed; S10. Wait for the winding to be completed, release the three-jaw chuck, move the slider and the shaft to the rightmost end, and remove the coil frame and the coil.

2. A winding device for a thin wire and small inner diameter coil, characterized in that: include: A base that provides stability and load-bearing function; A wire arrangement mechanism, the wire arrangement mechanism comprises a mounting bracket, a driving motor, a belt transmission device, a screw rod, a threaded slider, a wire arrangement shaft, a wire arrangement tube, a pre-tightening device and an adjusting steering gear, the mounting bracket is fixedly mounted on the base, the mounting bracket is mounted with a driving motor, the shaft end of the driving motor is connected with a screw rod through a belt transmission device, the screw rod is rotatably mounted on the mounting bracket, a threaded slider is threadedly mounted on the screw rod, a wire arrangement shaft is fixedly mounted on the threaded slider, the wire arrangement shaft passes through the mounting bracket, the wire arrangement shaft is slidably mounted between the mounting bracket and the base, the wire arrangement tube and the pre-tightening device are both mounted on the wire arrangement shaft, and the adjusting steering gear is mounted on the connecting rod of the pre-tightening device; A rotating mechanism, the rotating mechanism comprising a rotating motor, a spindle and a three-jaw chuck, the rotating motor being fixedly mounted on the base, the shaft end of the rotating motor passing through the base, the spindle being fixedly mounted on the shaft end of the rotating motor, and the three-jaw chuck being fixedly mounted on the spindle; A skeleton platform mechanism, the skeleton platform mechanism includes a y-axis adjustment knob, an x-axis adjustment knob, an x-axis adjustment module, a y-axis adjustment module, a screw transmission block, a fastening block one, a fastening block two and a screw, the y-axis adjustment module is vertically fixedly installed on the screw transmission block, clamped by the fastening block one and the fastening block two, and then installed by bolt connection, the x-axis adjustment module is horizontally installed on the y-axis adjustment module by bolts, and at the same time, there is a hole in the center of the x-axis adjustment module for fixing the winding shaft, and the above-mentioned hole and the three-jaw chuck together fix the winding shaft and the skeleton.

3. The winding device for a thin wire and small inner diameter coil according to claim 2, characterized in that: The belt transmission device includes a first pulley, a belt and a second pulley. The first pulley is fixedly mounted on the shaft end of the driving motor. The belt connects the first pulley and the second pulley. The second pulley is fixedly mounted on one end of the screw rod.

4. The winding device for a thin wire and small inner diameter coil according to claim 2, characterized in that: The supporting part of the cable duct is composed of a fixed rod, a connecting spring, a movable rod and a connecting cover. The fixed rod is fixedly installed on the cable duct shaft. The connecting spring connects the fixed rod and the movable rod. A connecting cover is fixedly installed on the movable rod. The connecting cover is movably installed on the fixed rod.

5. The winding device for a thin wire and small inner diameter coil according to claim 4, characterized in that: A fixing plate is fixedly mounted on the fixing rod, a telescopic member is mounted on the fixing plate, a contact switch is fixedly mounted on the shaft end of the telescopic member, the contact switch is matched with the connecting cover, and an output end of the contact switch is electrically connected to a control end of the rotating motor.

6. The winding device for a thin wire and small inner diameter coil according to claim 2, characterized in that: It also includes a camera module for photographing the winding shaft and two electromagnet modules used in conjunction with the camera module. The camera module is installed on the x-axis adjustment module, facing the winding shaft, and the two electromagnet modules are located below and to the side of the tungsten steel shaft.

7. The winding device for a thin wire and small inner diameter coil according to claim 2, characterized in that: It also includes a tension sensor for monitoring the tension of the wound copper wire and an active wire feeding mechanism for conveying the wound copper wire. The tension sensor is installed horizontally below the wire arranging tube, and the active wire feeding mechanism is installed horizontally directly below the wire arranging tube.

8. The winding device for a thin wire and small inner diameter coil according to claim 2, characterized in that: The threaded surface of the screw rod is located within the range of the mounting bracket; the wire arrangement shaft is parallel to the screw rod, and the wire arrangement shaft is a stainless steel structure.

9. The winding device for a thin wire and small inner diameter coil according to claim 2, characterized in that: The wire arranging tube is installed above the wire arranging shaft, and the pre-tightening device is installed below the wire arranging shaft; the main shaft matches the shaft support.

10. The winding device for a thin wire and small inner diameter coil according to claim 4, characterized in that: The fixed rod and the movable rod have the same size, and the fixed rod and the movable rod are spaced 50 mm apart.

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