High-precision copper wire coil mechanical winding forming device and winding method

Abstract

The invention discloses a high-precision copper wire coil mechanical winding forming device and a winding method, and belongs to the technical field of coil forming winding, the high-precision copper wire coil mechanical winding forming device comprises a pay-off mechanism, a wire arranging mechanism, a driving mechanism, a winding mechanism, an external acting mechanism, a heating mechanism, an overturning material taking mechanism, a wire arranging mechanism and other core components, and the characteristics and winding requirements of cables are fully considered. The cable can be wound comprehensively and completely without layering, and a series of series actions such as accurate paying-off, vertical winding displacement, high-speed winding, wire shaping, fixed overturning, wire end bevel arrangement, finished product taking and discharging and the like can be achieved. According to the high-precision copper wire coil mechanical winding forming device and the winding method, the large-batch and stable-quality production requirements can be met, the production cost and the labor cost are reduced, due to the fact that interference of human factors is reduced, the consistency and the reliability of products can be improved, high flexibility and expandability are achieved, and the high-precision copper wire coil mechanical winding forming device and the winding method are suitable for popularization and application. And adjustment and optimization can be carried out according to requirements.

Description

Technical Field

[0001] The invention relates to the technical field of coil forming and winding, and in particular to a high-precision copper wire coil mechanical winding forming device and a winding method. Background Art

[0002] In the existing technology, with the development of science and technology, the demand for VCM voice coil motors in precision instruments such as mobile phone cameras has increased. As a key component for realizing the autofocus function, it needs to have high precision and high production capacity to meet market demand.

[0003] There are many problems with traditional VCM coil winding. Manual operation is inefficient and has poor precision. Mechanized production using mold clamping is difficult for small VCM coils, making it difficult to clamp the molds and ensure precision, and it cannot meet production capacity requirements. As the core component of the VCM voice coil motor, the VCM coil has extremely high precision requirements. If the finished winding is stored manually, the method is simple and the coil is easily damaged, affecting product quality.

[0004] The vigorous development of high-tech industries has prompted the continuous improvement of production equipment towards high precision, high capacity and high automation. The fully automatic VCM winding and film laminating machine conforms to this development trend, which can effectively improve production efficiency and product quality and reduce labor costs. Summary of the invention

[0005] The purpose of the present invention is to provide a high-precision copper wire coil mechanical winding forming device and winding method, which can meet the production needs of large quantities and stable quality, reduce production costs and labor costs, reduce the interference of human factors, improve product consistency and reliability, and also have high flexibility and scalability, and can be quickly adjusted and optimized according to market demand.

[0006] To achieve the above-mentioned purpose, the present invention provides a high-precision copper wire coil mechanical winding and forming device, including a machine platform, a saddle base located at the front end is installed on the machine platform, a wire-releasing mechanism fixed on the machine platform is installed on the left side of the saddle base, which is used to control the wire to enter the wire-arranging mechanism installed on its right side, the wire-arranging mechanism is installed on the left end platform of the saddle base, and the lower end of the wire-arranging mechanism is provided with a driving mechanism fixed in the saddle base, the driving mechanism passes through the saddle base to drive the winding mechanism for winding, the winding mechanism is fixed at the front end of the driving mechanism and is located at the central position of the saddle base to avoid air; an external action mechanism located on the right side of the winding mechanism is installed at the inner wall position of the right end of the saddle base; a heating mechanism is installed at the bottom of the saddle base for hot-melt shaping of the outer surface of the wire; a flipping and material-retrieving mechanism is installed on the right end platform of the saddle base for transferring the wound coil to the wire-arranging mechanism, and the wire-arranging mechanism is installed on the machine platform and located at the rear end of the saddle base.

[0007] Preferably, the wire-releasing mechanism includes a servo tensioner and a tensioner support assembly, the bottom of the tensioner support assembly is fixed to the machine platform by bolts, and the servo tensioner is fixed to the top of the tensioner support assembly to maintain the stability of the wire tension.

[0008] Preferably, the wire arrangement mechanism includes a transverse movement component and a vertical wire feeding component, the transverse movement component includes a wire arrangement transverse movement servo motor and a wire arrangement transverse movement module, the bottom of the wire arrangement transverse movement module is fixed to the left end platform of the saddle base by bolts; the vertical wire feeding assembly is installed on the wire arrangement transverse movement module, and includes a vertical wire feeding servo motor, a vertical wire feeding screw rod, a vertical wire feeding guide rail, a cutter, a wire arrangement fixed wire clamp, a cutter control cylinder, an anti-jump device and a precision wire passing wheel, the vertical wire feeding servo motor is installed on the top of the vertical wire feeding guide rail, the vertical wire feeding screw rod is connected to the bottom of the vertical wire feeding servo motor, a vertical slider connected to the vertical wire feeding guide rail is installed on the vertical wire feeding screw rod, the cutter control cylinder is installed at the bottom of the vertical slider, and the cutter is connected to the front end of the cutter control cylinder; a fixed frame is installed on the side of the vertical slider, and the anti-jump device, the precision wire passing wheel and the wire arrangement fixed wire clamp are installed on the fixed frame from top to bottom in sequence.

[0009] Preferably, the driving mechanism includes a right-end feed drive component and a left-end rotation drive component, the right-end feed drive component includes a feed-end servo motor, a feed-end synchronous pulley, a feed-end screw and a feed-end transmission shaft connected in sequence; the left-end rotation drive component includes a rotation-end servo motor, a rotation-end synchronous pulley and a rotation-end transmission shaft connected in sequence.

[0010] Preferably, the winding mechanism includes a left umbrella mold and a right umbrella mold assembly; the left umbrella mold is fixed to the front end of the left end rotation drive assembly by machine screws, and a mold core through groove is provided at the upper end of the left umbrella mold; the right umbrella mold assembly includes a spindle flange, a split mold core, an incoming wire lead clamp assembly, an outgoing wire lead clamp assembly, a winding scale disk and a counterweight block; the spindle flange located at the rear end of the right umbrella mold assembly is fixed to the front end of the feed end transmission shaft by machine screws, and the front end of the spindle flange is connected to the split mold core, and the split mold core is in contact with the left umbrella mold; the split mold core includes a mold core, a mold core clamping block and a wire plate The core clamping block is installed at the lower end of the core, the wire board is fastened inside the spindle flange and is located at the front end of the core clamping block and the core, and a lead groove is provided at the upper end of the wire board to fix the lead wire and constrain the wire to wrap around the split core; the inner ring of the spindle flange is serially fixed to the split core and the feed end transmission shaft of the right end feed drive assembly through key pins, and the cylindrical surface of the spindle flange is covered with holes; the scale disk is installed at the front end of the wire board to accurately confirm the lead position and judge the number of turns; the incoming lead clamp assembly, the outgoing lead clamp assembly and the counterweight block are all installed on the outside of the bottom of the scale disk.

[0011] Preferably, the external acting mechanism includes an acting cylinder, an inlet wire clamp ring and an outlet wire clamp ring, the inlet wire clamp ring and the outlet wire clamp ring are arranged in concentric rings, and the acting cylinder is installed below the inlet wire clamp ring and the outlet wire clamp ring; the acting cylinder, the inlet wire clamp ring and the outlet wire clamp ring are connected through a wire clamp disc support seat, and the wire clamp disc support seat is fastened to the inner wall of the saddle base by installing a fixing block and bolts.

[0012] Preferably, the heating mechanism comprises a hot air gun propulsion assembly and a hot air gun, the hot air gun is mounted on the hot air gun propulsion assembly, and the hot air gun propulsion assembly is adjacent to the saddle base.

[0013] Preferably, the flipping and picking mechanism includes a finished product transfer assembly, a support and transverse movement assembly and a flipping wire clamp assembly, and the flipping wire clamp assembly includes a core, a stripping plate and an in-and-out lead transfer wire clamp; the flipping wire clamp assembly is installed at one end of the support and transverse movement assembly close to the saddle base, and is used to complete the handover and transfer of the coil, and the finished product transfer assembly is installed at one end of the support and transverse movement assembly away from the saddle base, and is used for finished product transfer and unloading; the support and transverse movement assembly is installed on the machine platform.

[0014] Preferably, the wire management mechanism includes a wire management platform located in the center, and an input lead angle wire clamp and an output lead angle wire clamp are arranged on the outside of the wire management platform, and the bottoms of the input lead angle wire clamp and the output lead angle wire clamp are respectively connected to a wire management motor through gears; fine-tuning micrometers are provided at both ends of the wire management platform.

[0015] The present invention also provides a winding method of a high-precision copper wire coil mechanical winding forming device, comprising the following steps: S1, servo tensioner pay-off; The wire passes through the servo tensioner on the wire-releasing mechanism and goes down into the wire-arranging mechanism; S2, the wire enters the cable fixing clamp; The wire passes through the anti-jump device of the wire arrangement mechanism and enters the three precision wire wheels at the bottom, and then is clamped by the wire arrangement fixed clamp below; S3, prepare winding; The action cylinder on the external action mechanism extends to push the wire feed clamp ring upward, open the wire feed lead clamp assembly on the winding mechanism, the vertical slider on the vertical wire feeding assembly at the front end of the wire arrangement mechanism extends downward, cooperates with the lateral movement assembly to move horizontally, the wire arrangement fixed wire clamp feeds the wire into the wire feed lead clamp assembly in the winding mechanism, the wire feed clamp ring descends, the wire feed lead clamp assembly merges and clamps the wire, the wire arrangement mechanism pulls back to feed the wire into the wire groove at the front end of the split mold core in the right umbrella mold assembly, the right end feed drive assembly in the drive mechanism cooperates to extend forward, and the left umbrella mold and the right umbrella mold assembly are molded; S4, start winding; The left end rotation drive assembly of the driving mechanism drives the rotation end transmission shaft to rotate at high speed, and the right end feed drive assembly drives the feed end transmission shaft to feed slowly. The coil is wound around the split mold core. After the set number of turns are wound, the lead wire is sent into the outlet lead clamp assembly by the wire arrangement fixed clamp at a fixed angle. The outlet lead clamp assembly is closed, and the hot air gun pushing assembly in the heating mechanism pushes the hot air gun into the winding work area. The winding mechanism rotates, and the hot air gun supplies heat to melt the surface of the wire and shape the wire. S5, turning over and taking out the material; The mold is opened, the flip wire clamp assembly is moved horizontally, the front end is taken out, the core of the flip wire clamp assembly is taken out of the shaped coil, the external inlet and outlet lead wire transfer clamp clamps the inlet and outlet leads, the inlet lead clamp assembly and the outlet lead clamp assembly in the right umbrella mold assembly release the leads, the flip wire clamp assembly is moved out of the saddle base and flipped 90 degrees longitudinally, so that the coil is downward and moved above the wire management platform; S6, lead angle adjustment; The inlet lead angle clamp and the outlet lead angle clamp in the wire management mechanism are opened, the inlet and outlet lead transfer clamp of the flip wire clamp assembly transfers the inlet and outlet leads to the inlet lead angle clamp and the outlet lead angle clamp, the stripping plate in the flip wire clamp assembly removes the shaped coil from the core and places it on the wire management platform, and the inlet lead angle clamp and the outlet lead angle clamp are closed; two wire management motors drive the inlet lead angle clamp and the outlet lead angle clamp to rotate around the wire management platform to a set angle, pull the lead to complete the inlet and outlet lead head angle fixing angle, and the wire management is completed; S7, finished product transfer and unloading; The finished product transfer component in the flip material taking mechanism takes the finished product out of the wire management platform and transfers it to the rear-end workstation.

[0016] Therefore, the present invention adopts the above-mentioned high-precision copper wire coil mechanical winding forming device and winding method to meet the production needs of large quantities and stable quality, reduce production costs and labor costs, and reduce the interference of human factors. It can improve the consistency and reliability of the product. It also has high flexibility and scalability, and can be quickly adjusted and optimized according to market demand.

[0017] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the back structure of an overall embodiment of a high-precision copper wire coil mechanical winding forming device of the present invention; Figure 2 It is a structural schematic diagram of a wire-releasing mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention; Figure 3 It is a structural schematic diagram of a wire arrangement mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention; Figure 4 It is a structural schematic diagram of a transverse movement assembly of a high-precision copper wire coil mechanical winding forming device of the present invention; Figure 5 It is a structural schematic diagram of a vertical wire feeding assembly of a high-precision copper wire coil mechanical winding forming device of the present invention; Figure 6 It is a structural schematic diagram of a driving mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention; Figure 7 It is a structural schematic diagram of a right-end feed drive assembly of a high-precision copper wire coil mechanical winding forming device of the present invention; Figure 8 It is a structural schematic diagram of a left end rotating driving assembly of a high-precision copper wire coil mechanical winding forming device of the present invention; Fig. 9 It is a structural schematic diagram of a winding mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention; Fig.10 It is a structural schematic diagram of an external action mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention; Fig.11 It is a structural schematic diagram of a heating mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention; Fig.12 It is a structural schematic diagram of a turning and picking mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention; Fig.13 It is a structural schematic diagram of a flip wire clamp assembly of a high-precision copper wire coil mechanical winding forming device of the present invention; Fig.14 It is a structural schematic diagram of a wire management mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention; Fig.15 It is a structural schematic diagram of a right umbrella mold assembly of a high-precision copper wire coil mechanical winding forming device of the present invention.

[0019] Reference numerals 1. Wire-releasing mechanism; 2. Wire-arranging mechanism; 3. Driving mechanism; 4. Wire-winding mechanism; 5. External action mechanism; 6. Heating mechanism; 7. Flipping and picking mechanism; 8. Wire-management mechanism; 9. Machine; 10. Saddle base; 2-1. Servo tensioner; 2-2. Tensioner support assembly; 3-1. Transverse shift assembly; 3-1-1. Wire-arranging transverse shift servo motor; 3-1-2. Wire-arranging transverse shift module; 3-2. Vertical wire-feeding assembly; 3-2-1. Vertical wire-feeding servo motor ;3-2-2, vertical wire feeding screw rod;3-2-3, vertical wire feeding guide rail;3-2-4, cutter;3-2-5, wire arrangement fixing clamp;3-2-6, cutter control cylinder;3-2-7, anti-jump device;3-2-8, precision wire passing wheel;4-1, right end feed drive assembly;4-1-1, feed end servo motor;4-1-2, feed end synchronous pulley;4-1-3, feed end screw rod;4-1-4, feed end transmission shaft;4-2, left end rotary Rotating drive assembly; 4-2-1, servo motor at rotating end; 4-2-2, synchronous pulley at rotating end; 4-2-3, transmission shaft at rotating end; 5-1, left umbrella mold; 5-2, right umbrella mold assembly; 6-1, top inlet clamp ring; 6-2, top outlet clamp ring; 6-3, working cylinder; 6-4, clamping plate support seat; 6-5, installation fixing block; 7-1, hot air gun propulsion assembly; 7-2, hot air gun; 8-1, finished product transfer assembly; 8-2, support transverse shifting assembly Parts; 8-3, flip wire clamp assembly; 8-3-1, core; 8-3-2, inlet and outlet lead transfer clamp; 9-1, wire management platform; 9-2, inlet lead angle wire clamp assembly; 9-3, outlet lead angle wire clamp assembly; 9-4, servo motor; 9-5, gear; 11-1, spindle flange; 11-2, split mold core; 11-3, inlet lead clamp assembly; 11-4, outlet lead clamp assembly; 11-5, counterweight; 11-6, winding scale disk. DETAILED DESCRIPTION

[0020] The technical solution of the present invention is further described below through the accompanying drawings and embodiments.

[0021] Unless otherwise defined, the technical terms or scientific terms used in the present invention should be understood by people with ordinary skills in the field to which the present invention belongs. The words "first", "second" and similar words used in the present invention do not indicate any order, quantity or importance, but are only used to distinguish different components. "Include" or "comprise" and similar words mean that the elements or objects appearing before the word include the elements or objects listed after the word and their equivalents, without excluding other elements or objects. "Connect" or "connected" and similar words are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. "Up", "down", "left", "right" and the like are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0022] Embodiment 1 As shown in the figure, the present invention provides a high-precision copper wire coil mechanical winding and forming device, including a machine table 9, on which a saddle base 10 located at the front end is installed, and a wire-releasing mechanism 1 fixed on the machine table 9 is installed on the left side of the saddle base 10, which is used to control the wire to enter the wire-arranging mechanism 2 installed on the right side thereof, and the wire-arranging mechanism 2 is installed on the left end platform of the saddle base 10, and the lower end of the wire-arranging mechanism 2 is provided with a driving mechanism 3 fixed in the saddle base 10, and the driving mechanism 3 passes through the saddle base 10 to drive the winding mechanism 4 for winding, and the winding mechanism 4 is fixed at the front end of the driving mechanism 3, and is located at the central position of the saddle base 10 to avoid air.

[0023] An external action mechanism 5 is installed on the right side of the winding mechanism 4 at the inner wall position of the right end of the saddle base 10. A heating mechanism 6 is installed at the bottom of the saddle base 10 for hot-melting the outer surface of the wire. A flip material taking mechanism 7 is installed on the right end platform of the saddle base 10 for transferring the wound coil to the wire management mechanism 8. The wire management mechanism 8 is installed on the machine platform 9 and is located at the rear end of the saddle base 10.

[0024] The pay-off mechanism 1 includes a servo tensioner 2-1 and a tensioner support assembly 2-2. The pay-off mechanism 1 is installed on the upper part of the machine platform 9, the bottom of the tensioner support assembly 2-2 is fixed to the machine platform 9 by bolts, and the servo tensioner 2-1 is fixed to the top of the tensioner support assembly 2-2. The servo tensioner 2-1 automatically adjusts the pulling force on the wire according to the preset tension value to maintain the stability of the wire tension and ensure the tightness and uniformity of the winding.

[0025] The wire arrangement mechanism 2 is installed on the left end platform of the saddle base 10 for vertical wire arrangement, and is located at the right end of the wire release mechanism 1. The wire arrangement mechanism 2 includes a transverse movement component 3-1 and a vertical wire feeding component 3-2. The transverse movement component 3-1 includes a wire arrangement transverse movement servo motor 3-1-1 and a wire arrangement transverse movement module 3-1-2. The bottom of the wire arrangement transverse movement module 3-1-2 is fixed to the left end platform of the saddle base 10 by bolts, which controls the transverse movement of the wire arrangement mechanism 2 and accurately positions it above the winding mechanism 4, while avoiding interference and collision with the flipping and picking mechanism 7. The vertical wire feeding assembly 3-2 is installed at the front end of the transverse movement assembly 3-1, including a vertical wire feeding servo motor 3-2-1, a vertical wire feeding screw rod 3-2-2, a vertical wire feeding guide rail 3-2-3, a cutter 3-2-4, a wire arrangement fixed wire clamp 3-2-5, a cutter control cylinder 3-2-6, an anti-jump device 3-2-7 and a precision wire passing wheel 3-2-8. The anti-jump device 3-2-7 and three precision wire passing wheels 3-2-8 are used in conjunction with the wire arrangement fixed wire clamp 3-2-5 to ensure the stability of the wire arrangement. The vertical wire feeding servo motor 3-2-1 is used in conjunction with the vertical wire feeding wire. The rod 3-2-2 and the vertical wire feeding guide rail 3-2-3 realize the longitudinal wire feeding into the wire lead clamp assembly in the winding mechanism 4. The vertical wire feeding screw rod 3-2-2 is equipped with a vertical slider connected to the vertical wire feeding guide rail 3-2-3. The cutter control cylinder 3-2-6 is installed at the bottom of the vertical slider, and the cutter 3-2-4 is connected to the front end of the cutter control cylinder 3-2-6. A fixed frame is installed on the side of the vertical slider. The anti-jump device 3-2-7, the precision wire wheel 3-2-8 and the wire arrangement fixed wire clamp 3-2-5 are installed on the fixed frame from top to bottom. After the winding is completed, the cutter control cylinder 3-2-6 extends, the cutter 3-2-4 cuts the wire, and the wire arrangement fixed wire clamp 3-2-5 still clamps the lead head, ensuring the continuity of the winding.

[0026] The driving mechanism 3 includes a right-end feed driving component 4-1 and a left-end rotation driving component 4-2. The driving mechanism 3 is fixed in the saddle base 10, located at the lower end of the wire arrangement mechanism 2, and passes through the saddle base 10 to drive the winding mechanism 4 for winding. The right-end feed driving component 4-1 is equipped with a feed-end servo motor 4-1-1, and uses the feed-end synchronous pulley 4-1-2 to drive and cooperate with the feed-end screw 4-1-3 to convert the rotational motion of the feed-end transmission shaft 4-1-4 into a linear feed motion. To achieve the simultaneous rotational feeding motion, the left-end rotation driving component 4-2 is controlled and driven by the rotation-end servo motor 4-2-1, and the rotation-end synchronous pulley 4-2-2 drives the rotation-end transmission shaft 4-2-3 to perform high-speed rotation motion, and cooperate to complete precision winding.

[0027] The winding mechanism 4 is fixed at the front end of the driving mechanism 3 at both ends, and is located at the center of the saddle base 10. The winding mechanism 4 includes a left umbrella mold 5-1 and a right umbrella mold assembly 5-2. The left umbrella mold 5-1 is fixed to the front end of the left end rotating driving assembly 4-2 by a machine screw, and the right umbrella mold assembly 5-2 is pressed against the winding process to limit the distance of the wire lateral arrangement and the winding wire drawing. The right umbrella mold assembly 5-2 includes a spindle flange 11-1, a split mold core 11-2, an incoming lead clamp assembly 11-3, an outgoing lead clamp assembly 11-4, a counterweight 11-5 and a winding scale disk 11-6. The spindle flange 11-1 located at the rear end of the right umbrella mold assembly 5-2 is fixedly installed on the front end of the feed end transmission shaft 4-1-4 by machine screws. The front end of the spindle flange 11-1 is connected to the split mold core 11-2. The split mold core 11-2 is in contact with the left umbrella mold 5-1. Both use special materials with special heat treatment and surface treatment to achieve a non-stick coil layer during the winding process.

[0028] The split mold core 11-2 includes a mold core, a mold core clamping block and a wire plate. The mold core clamping block is installed at the lower end of the mold core. The wire plate is fastened inside the spindle flange 11-1 and is located at the front end of the mold core clamping block and the mold core. The upper end of the wire plate is provided with a lead groove to fix the lead wire and constrain the wire to wrap around the split mold core. The inner ring of the spindle flange 11-1 is serially fixed to the split mold core and the feed end transmission shaft 4-1-4 of the right end feed drive assembly 4-1 through a key pin, and the cylindrical surface of the spindle flange 11-1 is covered with holes.

[0029] The winding scale disk 11-6 is installed at the front end of the wire board, which can accurately confirm the lead position and determine the number of turns. The incoming lead clamp assembly 11-3, the outgoing lead clamp assembly 11-4 and the counterweight 11-5 are all installed on the outside of the bottom of the winding scale disk 11-6. The incoming lead clamp assembly 11-3 and the outgoing lead clamp assembly 11-4 are used to fix the incoming and outgoing lead heads during the winding process. The counterweight 11-5 increases the weight of the winding scale disk 11-6 to ensure the stability of the high-speed rotating winding process.

[0030] The incoming wire lead clamp assembly 11-3 includes an incoming wire clamp, an end wire spring pressure rod, a first end wire spring pressure block and a first wire clamp spring. The incoming wire lead clamp assembly is installed at the bottom of the winding scale disk and is installed on the extension line of the lead groove. The first end wire spring pressure block is supported by the top incoming wire clamp ring 6-1 in the external external action mechanism 5, driving the end wire spring pressure rod to rotate, controlling the opening of the wire clamp, and the first wire clamp spring controls the reset to close the wire clamp.

[0031] The lead-out wire clamp assembly 11-4 includes a lead-out wire clamp seat, an end-line clamp, a clamp shaft, a second end-line spring pressure block and a second clamp spring. The lead-out wire clamp assembly is installed at the bottom of the winding scale disk and the installation position is at the required position. The top lead-out wire clamp ring 6-2 in the external external action mechanism 5 supports the second end-line spring pressure block, driving the clamp shaft to rotate and control the opening of the clamp. The second clamp spring controls the reset and closes the clamp.

[0032] The counterweight 11-5 is distributed at the bottom of the winding scale disk 11-6 and is installed in other arc-shaped waist grooves except the incoming lead clamp assembly 11-3 and the outgoing lead clamp assembly 11-4 to balance the center of the entire right umbrella mold assembly 5-2 and ensure the stability of the winding.

[0033] The external action mechanism 5 is installed on the inner wall of the right end of the saddle base 10, between the winding mechanism 4 and the right wall of the saddle base 10. The external action mechanism 5 includes an inlet clamp ring 6-1, an outlet clamp ring 6-2 and an action cylinder 6-3, all of which are connected through a clamping plate support seat 6-4, and the clamping plate support seat 6-4 is fastened to the inner wall of the saddle base 10 through a mounting fixing block 6-5 and bolts. The extension and retraction of the action cylinder 6-3 controls the rise and fall of the inlet clamp ring 6-1 and the outlet clamp ring 6-2, and the upper top controls the opening and closing of the inlet lead clamp assembly and the outlet lead clamp assembly in the winding mechanism 4, and cooperates to clamp the inlet and outlet lead heads at the beginning and end of winding.

[0034] The heating mechanism 6 is installed on the bottom side of the saddle base 10, and is used to perform heat-melting shaping on the outer surface of the wire. The heating mechanism 6 includes a hot air gun pushing assembly 7-1 and a hot air gun 7-2. The hot air gun pushing assembly 7-1 is close to the saddle base 10. On the one hand, it supports and fixes the hot air gun 7-2, and on the other hand, it pushes the hot air gun 7-2 upward obliquely to the winding work area to provide a sufficient temperature environment. At the same time, when the flipping material taking mechanism 7 comes to take the material, it can be retracted to avoid interference.

[0035] The flipping and picking mechanism 7 is installed on the platform at the right end of the saddle base 10. After the coil winding is completed, the flipping and picking mechanism 7 transfers the coil to the wire management platform. The flipping and picking mechanism 7 includes a finished product transfer component 8-1, a support transverse movement module 8-2 and a flipping wire clamp component 8-3. The flipping wire clamp component 8-3 includes a core, a stripping plate and an in-and-out lead wire transfer clamp, which is installed at the end of the support transverse movement component 8-2 close to the saddle base 10. The handover and transfer of the coil is completed by transverse movement between the wire management mechanism 8 and the saddle base 10, and the finished product transfer component 8-1 is installed at the end of the support transverse movement component 8-2 away from the saddle base 10, which is used for finished product transfer and unloading. The support transverse movement component 8-2 is installed on the machine table 9 to complete stable transverse movement.

[0036] The wire management mechanism 8 is installed on the machine 9 at the rear end of the saddle base 10 to shape the lead head of the shaped coil. After the shaping is successful, it is a finished coil. The wire management mechanism 8 includes a wire management platform located in the center, and the outer side of the wire management platform is provided with an inlet lead angle clamp and an outlet lead angle clamp. The bottom of the inlet lead angle clamp and the outlet lead angle clamp are respectively connected to the wire management motor through gears, and fine-tuning micrometers are provided at both ends of the wire management platform.

[0037] The core structure of the wire management mechanism 8 is the coordination of the wire management platform 9-1 with the lead-in angle wire clamp 9-2 and the lead-out angle wire clamp 9-3. The two wire management motors installed at the bottom drive the lead-in angle wire clamp 9-2 and the lead-out angle wire clamp 9-3 above to rotate around the central wire management platform 9-1 through gear transmission. At the same time, the fine-tuning micrometers at both ends of the wire management platform 9-1 adjust the position of the wire management platform. The wire management mechanism 8 can avoid the enameled wire from crossing and winding, ensuring that each circle of enameled wire can be accurately wound at the predetermined position to ensure the quality and performance of the coil. The wire management mechanism 8 can also adjust the tension in real time to keep the tension within an appropriate range to ensure the tightness and uniformity of the winding.

[0038] The present invention also provides a winding method of a high-precision copper wire coil mechanical winding forming device, comprising the following steps: S1, servo tensioner 2-1 pays off; The wire passes through the servo tensioner 2 - 1 on the wire-releasing mechanism 1 and enters the wire-arranging mechanism 2 downward.

[0039] S2, the wire enters the cable fixing clamp 3-2-5; The wire passes through the anti-jump device 3-2-7 of the wire arrangement mechanism 2 and enters the three precision wire passing wheels 3-2-8 at the bottom, and is then clamped by the wire arrangement fixing clamp 3-2-5 at the bottom.

[0040] S3, prepare winding; The acting cylinder 6-3 on the external acting mechanism 5 extends to push the wire feed clamp ring 6-1 up, opens the wire feed lead clamp assembly 11-3 on the winding mechanism 4, and the vertical slider on the vertical wire feeding assembly 3-2 at the front end of the wire arranging mechanism 2 extends downward, cooperates with the transverse movement assembly 3-1 to move horizontally, and the wire arranging fixed clamp 3-2-5 feeds the wire into the wire feed lead clamp assembly 11-3 in the winding mechanism 4, pushes the wire feed clamp ring 6-1 down, and the wire feed lead clamp assembly 11-3 merges to clamp the wire, and the wire arranging mechanism 2 pulls back to feed the wire into the wire groove at the front end of the split mold core in the right umbrella mold assembly 5-2, and the right end feed drive assembly 4-1 in the drive mechanism 3 cooperates to extend forward, and the left umbrella mold 5-1 and the right umbrella mold assembly 5-2 are molded.

[0041] S4, start winding; The left end rotation drive component 4-2 of the driving mechanism 3 drives the rotating end transmission shaft 4-2-3 to rotate at high speed, and the right end feed drive component 4-1 drives the feed end transmission shaft 4-1-4 to feed slowly. The coil is wound around the split core 11-2. After winding the set number of turns, the lead wire is sent into the output lead clamp component 11-4 by the wire arrangement fixed clamp 3-2-5 at a fixed angle. The output lead clamp component 11-4 is closed, and the hot air gun pushing component 7-1 in the heating mechanism 6 pushes the hot air gun 7-2 into the winding working area. The winding mechanism 4 rotates, and the hot air gun 7-2 supplies heat to melt the surface of the wire and shape the wire.

[0042] S5, turning over and taking out the material; The mold is opened, the flip wire clamp assembly 8-3 is moved horizontally, the material is taken from the front end, the core 8-3-1 of the flip wire clamp assembly 8-3 takes out the shaped coil, the external inlet and outlet lead transfer clamp 8-3-2 clamps the inlet and outlet leads, the inlet lead clamp assembly 11-3 and the outlet lead clamp assembly 11-4 in the right umbrella mold assembly 5-2 release the leads, and the flip wire clamp assembly 8-3 is moved out of the saddle base 10 and flipped 90 degrees longitudinally to make the coil face downward and move it above the wire management platform.

[0043] S6, lead angle adjustment; The inlet lead angle clamp 9-2 and the outlet lead angle clamp 9-3 in the wire management mechanism 8 are opened, the inlet and outlet lead transfer clamp 8-3-2 of the flip clamp assembly 8-3 transfers the inlet and outlet leads to the inlet lead angle clamp 9-2 and the outlet lead angle clamp 9-3, the stripping plate in the flip clamp assembly 8-3 removes the shaped coil from the core 8-3-1, places it on the wire management platform 9-1, and the inlet lead angle clamp 0-2 and the outlet lead angle clamp 9-3 are closed; the two wire management motors 9-5 and 9-5 drive the inlet lead angle clamp 9-3 and the outlet lead angle clamp 9-4 to rotate around the wire management platform 9-1 to a set angle, pull the leads to complete the inlet and outlet lead head angle fixing angle, and the wire management is completed.

[0044] S7, finished product transfer and unloading; The finished product transfer assembly 8-1 in the flipping and picking mechanism 7 takes the finished product out of the line arrangement platform 9-1 and transfers it to the rear-end station.

[0045] Therefore, the present invention adopts the above-mentioned high-precision copper wire coil mechanical winding forming device and winding method, which can meet the production needs of large quantities and stable quality, reduce production costs and labor costs, and improve product consistency and reliability due to the reduction of interference from human factors. It also has high flexibility and scalability, and can be quickly adjusted and optimized according to market demand.

[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that they can still modify or replace the technical solution of the present invention with equivalents, and these modifications or equivalent replacements cannot cause the modified technical solution to deviate from the spirit and scope of the technical solution of the present invention.

Claims

1. A high-precision copper wire coil mechanical winding forming device, characterized in that: The machine comprises a saddle base at the front end being installed on the machine, a wire-releasing mechanism fixed on the machine is installed on the left side of the saddle base for controlling the wire to enter the wire-arranging mechanism installed on the right side thereof, the wire-arranging mechanism is installed on the platform at the left end of the saddle base, a driving mechanism fixed in the saddle base is arranged at the lower end of the wire-arranging mechanism, the driving mechanism passes through the saddle base to drive the winding mechanism for winding, the winding mechanism is fixed at the front end of the driving mechanism and is located at the central position of the saddle base where the saddle base is avoided; an external action mechanism located on the right side of the winding mechanism is installed on the inner wall at the right end of the saddle base; a heating mechanism is installed on the bottom of the saddle base for hot-melt shaping of the outer surface of the wire; a flipping and material-retrieving mechanism is installed on the platform at the right end of the saddle base for transferring the wound coil to the wire-arranging mechanism, the wire-arranging mechanism is installed on the machine and is located at the rear end of the saddle base.

2. A high-precision copper wire coil mechanical winding forming device according to claim 1, characterized in that: The wire-releasing mechanism comprises a servo tensioner and a tensioner support assembly. The bottom of the tensioner support assembly is fixed to the machine platform by bolts, and the servo tensioner is fixed to the top of the tensioner support assembly to maintain the stability of the wire tension.

3. The high-precision copper wire coil mechanical winding forming device according to claim 1 is characterized in that: The wire arrangement mechanism includes a transverse movement component and a vertical wire feeding component, the transverse movement component includes a wire arrangement transverse movement servo motor and a wire arrangement transverse movement module, the bottom of the wire arrangement transverse movement module is fixed to the left end platform of the saddle base by bolts; the vertical wire feeding component is installed on the wire arrangement transverse movement module, including a vertical wire feeding servo motor, a vertical wire feeding screw rod, a vertical wire feeding guide rail, a cutter, a wire arrangement fixed wire clamp, a cutter control cylinder, an anti-jump device and a precision wire passing wheel, the vertical wire feeding servo motor is installed on the top of the vertical wire feeding guide rail, the vertical wire feeding screw rod is connected to the bottom of the vertical wire feeding servo motor, the vertical wire feeding screw rod is installed with a vertical slider connected to the vertical wire feeding guide rail, the cutter control cylinder is installed at the bottom of the vertical slider, and the cutter is connected to the front end of the cutter control cylinder; a fixed frame is installed on the side of the vertical slider, and the anti-jump device, the precision wire passing wheel and the wire arrangement fixed wire clamp are installed on the fixed frame from top to bottom in sequence.

4. The high-precision copper wire coil mechanical winding forming device according to claim 1 is characterized in that: The driving mechanism includes a right-end feed drive component and a left-end rotation drive component. The right-end feed drive component includes a feed-end servo motor, a feed-end synchronous pulley, a feed-end screw and a feed-end transmission shaft connected in sequence; the left-end rotation drive component includes a rotation-end servo motor, a rotation-end synchronous pulley and a rotation-end transmission shaft connected in sequence.

5. A high-precision copper wire coil mechanical winding forming device according to claim 4, characterized in that: The winding mechanism comprises a left umbrella mold and a right umbrella mold assembly; the left umbrella mold is fixed to the front end of the left end rotation drive assembly by machine screws, and a mold core through groove is provided at the upper end of the left umbrella mold; the right umbrella mold assembly comprises a spindle flange, a split mold core, an incoming wire lead clamp assembly, an outgoing wire lead clamp assembly, a winding scale disk and a counterweight block; the spindle flange located at the rear end of the right umbrella mold assembly is fixed to the front end of the feed end transmission shaft by machine screws, and the front end of the spindle flange is connected to the split mold core, and the split mold core is in contact with the left umbrella mold; the split mold core comprises a mold core, a mold core clamping block and a wire plate. The core clamping block is installed at the lower end of the core, the wire board is fastened to the inside of the spindle flange and is located at the front end of the core clamping block and the core, and a lead groove is provided at the upper end of the wire board to fix the lead wire and constrain the wire to wrap around the split core; the inner ring of the spindle flange is serially fixed to the split core and the feed end transmission shaft of the right end feed drive assembly through key pins, and the cylindrical surface of the spindle flange is covered with holes; the scale disk is installed at the front end of the wire board to accurately confirm the lead position and judge the number of turns; the incoming lead clamp assembly, the outgoing lead clamp assembly and the counterweight block are all installed on the outside of the bottom of the scale disk.

6. The high-precision copper wire coil mechanical winding forming device according to claim 1, characterized in that: The external acting mechanism includes an acting cylinder, an inlet wire clamp ring and an outlet wire clamp ring, the inlet wire clamp ring and the outlet wire clamp ring are arranged in concentric circles, and the acting cylinder is installed below the inlet wire clamp ring and the outlet wire clamp ring; the acting cylinder, the inlet wire clamp ring and the outlet wire clamp ring are connected through a wire clamping disc support seat, and the wire clamping disc support seat is fastened to the inner wall of the saddle base by installing a fixing block and bolts.

7. The high-precision copper wire coil mechanical winding forming device according to claim 1, characterized in that: The heating mechanism comprises a hot air gun propulsion assembly and a hot air gun, wherein the hot air gun is mounted on the hot air gun propulsion assembly, and the hot air gun propulsion assembly is adjacent to the saddle base.

8. The high-precision copper wire coil mechanical winding forming device according to claim 1, characterized in that: The flipping and picking mechanism includes a finished product transfer assembly, a support transverse movement assembly and a flipping wire clamp assembly, wherein the flipping wire clamp assembly includes a core, a stripping plate and an in-and-out lead wire transfer clamp; the flipping wire clamp assembly is installed at one end of the support transverse movement assembly close to the saddle base, and is used to complete the handover and transfer of the coil, and the finished product transfer assembly is installed at one end of the support transverse movement assembly away from the saddle base, and is used for finished product transfer and unloading; The supporting transverse movement assembly is installed on the machine platform.

9. The high-precision copper wire coil mechanical winding forming device according to claim 1, characterized in that: The wire management mechanism includes a wire management platform located in the center, and an inlet lead angle clamp and an outlet lead angle clamp are arranged on the outside of the wire management platform. The bottoms of the inlet lead angle clamp and the outlet lead angle clamp are respectively connected to wire management motors through gears; fine-tuning micrometers are provided at both ends of the wire management platform.

10. A winding method for a high-precision copper wire coil mechanical winding forming device according to any one of claims 1 to 9, characterized in that: The following steps are involved: S1, servo tensioner pay-off; The wire passes through the servo tensioner on the wire-releasing mechanism and goes down into the wire-arranging mechanism; S2, the wire enters the cable fixing clamp; The wire passes through the anti-jump device of the wire arrangement mechanism and enters the three precision wire wheels at the bottom, and then is clamped by the wire arrangement fixed clamp below; S3, prepare winding; The action cylinder on the external action mechanism extends, the push-in wire clamp ring rises, the wire-in lead clamp assembly on the winding mechanism is opened, the vertical slider on the vertical wire feeding assembly at the front end of the wire arrangement mechanism extends downward, and cooperates with the transverse movement assembly to move horizontally, the wire arrangement fixed wire clamp feeds the wire into the wire-in lead clamp assembly in the winding mechanism, the push-in wire clamp ring descends, the wire-in lead clamp assembly merges to clamp the wire, the wire arrangement mechanism pulls back and feeds the wire into the wire groove at the front end of the split mold core in the right umbrella mold assembly, the right end feed drive assembly in the drive mechanism cooperates to extend forward, and the left umbrella mold and the right umbrella mold assembly are molded; S4, start winding; The left end rotation drive assembly of the driving mechanism drives the transmission shaft to rotate at high speed, and the right end feed drive assembly drives the transmission shaft to feed slowly. The coil is wound around the split mold core. After the set number of turns are wound, the lead wire is sent into the outlet lead clamp assembly by the wire arrangement fixed clamp at a fixed angle. The outlet lead clamp assembly is closed, and the hot air gun pushing assembly in the heating mechanism pushes the hot air gun into the winding work area. The winding mechanism rotates, and the hot air gun supplies heat to melt the surface of the wire and shape the wire. S5, turning over and taking out the material; The mold is opened, the flip wire clamp assembly is moved horizontally, the front end is taken out, the core of the flip wire clamp assembly is taken out of the shaped coil, the external inlet and outlet lead wire transfer clamp clamps the inlet and outlet leads, the inlet lead clamp assembly and the outlet lead clamp assembly in the right umbrella mold assembly release the leads, the flip wire clamp assembly is moved out of the saddle base and flipped 90 degrees longitudinally, so that the coil is downward and moved above the wire management platform; S6, lead angle adjustment; The inlet lead angle clamp and the outlet lead angle clamp in the wire management mechanism are opened, the inlet and outlet lead transfer clamp of the flip wire clamp assembly transfers the inlet and outlet leads to the inlet lead angle clamp and the outlet lead angle clamp, the stripping plate in the flip wire clamp assembly removes the shaped coil from the core and places it on the wire management platform, and the inlet lead angle clamp and the outlet lead angle clamp are closed; two wire management motors drive the inlet lead angle clamp and the outlet lead angle clamp to rotate around the wire management platform to a set angle, pull the lead to complete the inlet and outlet lead head angle fixing angle, and the wire management is completed; S7, finished product transfer and unloading; The finished product transfer component in the flip material taking mechanism takes the finished product out of the wire management platform and transfers it to the rear-end workstation.

Images