Electromagnet coil framework and electromagnet production process

Abstract

The invention relates to the technical field of electromagnets, in particular to an electromagnet coil framework and an electromagnet production process, the top surface of a block body arranged at the top end of the front wall of a framework main body is provided with slots in pairs, terminals are inserted into the slots, and the front wall of the block body at the top end of the framework main body is provided with open slots corresponding to the slots. The process comprises the following steps: S1, conveying a framework main body and a terminal to an operation line through an automatic feeding machine; s2, grabbing the terminal by using a manipulator, and pressing the terminal into the slot of the framework main body; s3, winding a coil and removing an outer paint layer of the enameled wire by using a peeling girdling knife; s4, crimping an electric wire; s5, resistance welding; s6, resistance detection; s7, nesting a network pipe; s8, assembling and connecting the coil framework with the iron core and the iron shell; s9, carrying out injection molding filling on the pores of the inner cavity of the iron shell; s10, a milling cutter is adopted for conducting surface treatment on the injection molding structure; and S11, finished product detection. The problems that the efficiency is low and the cost is high in the production and machining process of the electromagnet are well solved.

Description

Technical Field

[0001] The invention relates to the technical field of electromagnets, in particular to an electromagnet coil frame and an electromagnet production process. Background Art

[0002] The applications of electromagnets in life include: household appliances (such as induction cookers, microwave ovens, washing machines, etc.), transportation (such as electromagnetic brake systems, maglev trains), safety equipment (such as electromagnetic locks, fire alarm systems), etc. Among them, an electromagnet is often used in electromagnetic brake systems, and its components mainly include: skeleton body, iron core, iron shell, wire, network tube, enameled wire, injection molding part and terminal.

[0003] Traditionally, the electromagnets used in electromagnetic brake systems often have a low degree of automation during production and processing, and many processes are completed manually. Due to the large number of production tasks, the number of products can only be increased by adding more people, equipment and working hours, and the labor cost is extremely disadvantageous.

[0004] In the above situation, in order to improve the degree of automation in electromagnet production and processing and reduce labor costs, it is urgent to optimize the electromagnet production process. Summary of the invention

[0005] The object of the present invention is to provide an electromagnet coil skeleton and an electromagnet production process, so as to solve the problem of low efficiency and high cost in the production and processing of electromagnets in the prior art.

[0006] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: an electromagnet coil skeleton, comprising a skeleton body, a block top surface arranged at the top of the front wall of the skeleton body is provided with slots in pairs, and an open slot is provided at the position of the block front wall at the top of the skeleton body corresponding to the slot; the slot is used for plugging in the terminal.

[0007] A process for producing an electromagnet comprises the following steps: S1. Put the skeleton body and the terminal into the material box of the feeding mechanism, and the skeleton body and the terminal are transported to the production line through the automatic feeding machine; S2. Use a robot to grab the terminal and press it into the slot of the skeleton body; S3, winding the coil and removing the outer paint layer of the enameled wire wound on the skeleton body by using a peeling ring cutter; Among them, one end of the enameled wire is first fixed to a terminal, and then the automatic winding is carried out. After the winding is completed, the outer paint layer of the enameled wire is removed by a peeling ring cutter, and the other end of the enameled wire is fixed to another terminal to complete the winding process. The traditional winding process is: manually install them one by one on the winding tooling, the enameled wire is manually fixed to the winding tooling, and automatic winding is carried out. After the winding is completed, the insulating paper is manually attached to the tape, and then rotated two times to fix the tape (automatic winding does not require insulating paper). The automatic winding used in the present invention is multi-station, which can realize the completion of multiple pieces at the same time, and the efficiency is greatly improved.

[0008] S4, crimping wires; Among them, the wire cutting mechanism is used to automatically transport the wires after the wire cutting and peeling to the crimping station, and the wires and terminals are crimped at one time. The traditional process of crimping wires is: before crimping the terminals, the wound coil enameled wires must be peeled. The peeling of the enameled wires is through a chemical reaction, and the paint layer is corroded with a paint stripper. Due to the changes in seasonal weather temperature, the effect of the enameled wire stripping is affected. If the paint is not removed cleanly, or it has to be repeated, it will affect the product quality and production efficiency. Moreover, the peeling is done manually one by one, first dipped in a paint stripper, placed, and then wiped with a rag, which is labor-intensive and time-consuming. The peeled coils are then crimped by a terminal press. Each coil is crimped twice. Therefore, the process of crimping wires not only greatly improves efficiency, but also improves the peeling quality of the enameled wires.

[0009] S5, resistance welding; Among them, the conductor of the enameled wire and the electric wire are fused through the resistance welding process; the conductive effect is more stable.

[0010] S6, resistance detection; Among them, qualified products that pass the resistance test will flow to the next process, and unqualified ones will automatically flow into the unqualified area; S7, network management set; The network tube is put on one end of the wire close to the terminal to protect the wire.

[0011] S8, assembly; Assemble the coil frame with the iron core and iron shell after winding; S9, injection molding; Injection molding is performed at the pores in the inner cavity of the iron shell; the coil skeleton, enameled wire, terminal, etc. are integrated with the iron shell through injection molding of PPS material.

[0012] S10, milling; The surface of the injection molding structure is flattened by a milling cutter; the electromagnet surface after flattening can better fit with the friction surface, thereby improving the friction force.

[0013] S11, finished product inspection; Among them, the finished electromagnets that pass the inspection will be transferred to the next process, and those that fail the inspection will be confirmed and processed according to the unqualified process.

[0014] Preferably, the annular cutting knife in step S3 is made of tungsten steel.

[0015] Preferably, the injection molding material in step S9 is a special engineering plastic PPS with excellent comprehensive performance. Compared with the prior art, the beneficial effects of the present invention are: 1. The present invention relates to an electromagnet coil frame and an electromagnet production process, which greatly saves manpower in the processes of wire cutting, coil winding, enameled wire peeling, terminal crimping, and mesh tube installation, and the overall production efficiency is greatly improved.

[0016] 2. The present invention relates to an electromagnet coil frame and an electromagnet production process which adopts an automatic winding process. The wire arrangement uniformity of the coil winding is improved compared with manual winding, and it is convenient to control the tensioning force of the enameled wire during winding. The winding arrangement is uniform and has good consistency, thereby greatly improving the performance stability of the product.

[0017] 3. The present invention relates to an electromagnet coil frame and an electromagnet production process that uses a peeling tungsten steel ring cutting knife, which can effectively remove the enameled wire paint layer, not only greatly improving the peeling efficiency of the enameled wire, but also improving the peeling quality, thereby ensuring good contact between the enameled copper wire and the electric wire, and greatly improving the performance stability of the product.

[0018] 4. The present invention relates to an electromagnet coil frame and an electromagnet production process in which a resistance welding process is added. Resistance welding does not require filler metal, has high production efficiency, and reduces deformation of welds. The resistance heat effect generated by the current flowing through the contact surface and adjacent areas of the workpieces is used to heat them to a molten or plastic state, so that the enameled wire conductor and the electric wire conductor are better integrated together, resulting in a better conductive effect.

[0019] 5. The present invention relates to an electromagnet coil frame and an electromagnet production process in which a resistance detection function is added. Each processed product must pass the resistance detection. Through the resistance detection, it is possible to identify unqualified products caused by abnormalities in the winding, peeling, welding and other processes. Qualified products will flow to the next process, and unqualified products will automatically flow into the unqualified area, thereby ensuring the quality of the electromagnet products. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the process flow of the electromagnet production process of the present invention; Figure 2 The cross-sectional structure diagram of the electromagnet in the electromagnet production process of the present invention is Figure 3 It is a schematic diagram of the three-dimensional structure of the electromagnet coil skeleton of the present invention.

[0021] In the figure: 1-frame body; 1.1-slot; 2- Iron core; 3- Iron shell; 4- Wires; 5- Network management; 6- enameled wire; 7-Injection molding structure; 8-terminal. DETAILED DESCRIPTION

[0022] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0023] See also Figure 3 The present invention provides a technical solution, an electromagnet coil skeleton, including a skeleton body 1, a block top surface arranged at the top of the front wall of the skeleton body 1 is provided with pairs of slots 1.1, and the slots 1.1 are used to plug in terminals 8; enameled wires 6 are wound around the skeleton body 1.

[0024] See also Figure 1-3 The present invention provides a technical solution, an electromagnet production process, comprising the following steps: S1, put the skeleton body 1 and the terminal 8 into the material box of the feeding mechanism, and the skeleton body 1 and the terminal 8 are transported to the production line by the automatic feeding machine; S2, using a manipulator to grab the terminal 8 and press it into the slot 1.1 of the skeleton body 1; S3, winding the coil and removing the outer paint layer of the enameled wire 6 wound around the skeleton body 1 using a peeling ring cutter; The ring cutting knife is made of tungsten steel. During operation, one end of the enameled wire 6 is first fixed to a terminal 8, and then the wire is automatically wound. After the winding is completed, the outer paint layer of the enameled wire 6 is removed by the peeling ring cutting knife, and the other end of the enameled wire 6 is fixed to another terminal 8 to complete the winding process; S4, crimping wire 4; The wire 4 after cutting and peeling is automatically transported to the crimping station by the wire cutting mechanism, and the wire 4 and the terminal 8 are crimped at one time; S5, resistance welding; Wherein, the enameled wire 6 and the conductor of the electric wire 4 are fused by a resistance welding process; S6, resistance detection; Among them, qualified products that pass the resistance test will flow to the next process, and unqualified ones will automatically flow into the unqualified area; S7, set network management 5; The network management unit 5 is mounted on one end of the wire 4 near the terminal 8; S8, assembly; Assemble and connect the coil frame with the iron core 2 and the iron shell 3 after winding; S9, injection molding; The injection molding material used is PPS material. An injection molding machine is used to perform injection molding filling in the inner cavity pores of the iron shell 3 to form an injection molding structure 7; S10, milling; The surface of the injection molding structure 7 is flattened by using a milling cutter; S11, finished product inspection; Among them, the finished electromagnets that pass the inspection will be transferred to the next process, and those that fail the inspection will be confirmed and processed according to the unqualified process.

[0025] It should be noted that in this article, relational terms such as first and second are only used to Distinguishes one entity or operation from another entity or operation without necessarily requiring or implying any such actual relationship or order between those entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0026] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An electromagnet coil frame, comprising a frame body (1), characterized in that: The top surface of the block arranged at the top end of the front wall of the skeleton body (1) is provided with pairs of slots (1.1), and the slots (1.1) are used for plugging in terminals (8).

2. A process for producing an electromagnet, the electromagnet having the coil frame according to claim 1, characterized in that: The following steps are involved: S1, placing the skeleton body (1) and the terminal (8) into a material box of a feeding mechanism, and conveying the skeleton body (1) and the terminal (8) to the production line through an automatic feeding machine; S2, using a robot to grab the terminal (8) and press it into the slot (1.1) of the skeleton body (1); S3, winding the coil and using a peeling ring cutting knife to remove the outer paint layer of the enameled wire (6) wound on the skeleton body (1); Wherein, one end of the enameled wire (6) is first fixed to a terminal (8), and then the wire is automatically wound. After the winding is completed, the outer paint layer of the enameled wire (6) is removed by a peeling ring cutting knife, and the other end of the enameled wire (6) is fixed to another terminal (8) to complete the winding process; S4, crimping wires (4); The wire (4) after wire cutting and peeling is automatically transported to a crimping station by a wire cutting mechanism, and the wire (4) and the terminal (8) are crimped at one time; S5, resistance welding; wherein the enameled wire (6) and the conductor of the electric wire (4) are fused together by a resistance welding process; S6, resistance detection; Among them, qualified products that pass the resistance test will flow to the next process, and unqualified ones will automatically flow into the unqualified area; S7, set network management (5); The network tube (5) is sleeved on one end of the electric wire (4) close to the terminal (8); S8, assembly; Assembling the coil frame after winding with the iron core (2) and the iron shell (3); S9, injection molding; Performing injection molding to fill the pores in the inner cavity of the iron shell (3); S10, milling; A milling cutter is used to flatten the surface of the injection molded structure (7); S11, finished product inspection; Among them, the finished electromagnets that pass the inspection will be transferred to the next process, and those that fail the inspection will be confirmed and processed according to the unqualified process.

3. The electromagnet production process according to claim 2, characterized in that: The ring cutting knife in step S3 is made of tungsten steel.

4. The electromagnet production process according to claim 2, characterized in that: The injection molding material in step S9 is PPS material.

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