A high-precision copper wire coil mechanical winding forming device and a winding method

Abstract

The application discloses a high-precision copper wire coil mechanical winding forming device and a winding method, and belongs to the technical field of coil forming and winding, which comprises core components such as a pay-off mechanism, a wire arranging mechanism, a driving mechanism, a winding mechanism, an external acting mechanism, a heating mechanism, a turnover material taking mechanism and a wire arranging mechanism, fully considers the characteristics and winding requirements of the cable, ensures that the cable can be fully and completely wound without layering, and can realize a series of series actions such as accurate pay-off, vertical wire arranging, high-speed winding, wire shaping, fixed turnover, wire head corner arrangement, finished product material taking and material feeding. The high-precision copper wire coil mechanical winding forming device and the winding method can meet the production requirements of large quantities and stable quality, reduce the production cost and the labor cost, improve the consistency and reliability of the product due to the reduction of human factors, and have high flexibility and expandability, and can be adjusted and optimized according to requirements.

Description

Technical Field

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

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

[0003] Traditional VCM coil winding has many problems: manual operation is inefficient and inaccurate; mechanized production using mold clamping is difficult for small VCM coils, making it hard to guarantee accuracy and unable to meet production capacity requirements. As the core component of the VCM voice coil motor, the VCM coil has extremely high precision requirements. If the wound coil is stored manually, the method is rudimentary and the coil is easily damaged, affecting product quality.

[0004] The booming development of high-tech industries has prompted continuous improvement in production equipment towards higher precision, higher capacity, and higher automation. The fully automatic VCM winding and laminating machine is in line with this development trend and can effectively improve production efficiency and product quality while reducing labor costs. Summary of the Invention

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

[0006] To achieve the above objectives, the present invention provides a high-precision copper wire coil mechanical winding forming device, comprising a machine base, a saddle base mounted on the front end of the machine base, a wire feeding mechanism fixed on the left side of the saddle base for controlling the wire to enter a wire laying mechanism mounted on its right side, the wire laying mechanism being mounted on the left end platform of the saddle base, a drive mechanism fixed in the saddle base being disposed at the lower end of the wire laying mechanism, the drive mechanism passing through the saddle base to drive the winding mechanism to wind the wire, the winding mechanism being fixed at the front end of the drive mechanism and located at the center of the saddle base; an external action mechanism located to the right of the winding mechanism being mounted on the inner wall of the right end of the saddle base; a heating mechanism being mounted at the bottom of the saddle base for heat-melting and shaping the outer surface of the wire; a flipping and picking mechanism being mounted on the right end platform of the saddle base for transferring the wound coil to a wire handling mechanism, the wire handling mechanism being mounted on the machine base and located at the rear end of the saddle base.

[0007] Preferably, the wire feeding mechanism includes a servo tensioner and a tensioner support assembly. The bottom of the tensioner support assembly is fixed to the machine base 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 cable laying mechanism includes a horizontal movement component and a vertical cable feeding component. The horizontal movement component includes a cable laying horizontal movement servo motor and a cable laying horizontal movement module. The bottom of the cable laying horizontal movement module is fixed to the left end platform of the saddle base by bolts. The vertical cable feeding component is installed on the cable laying horizontal movement module and includes a vertical cable feeding servo motor, a vertical cable feeding screw, a vertical cable feeding guide rail, a cutter, a cable laying fixing clamp, a cutter control cylinder, an anti-jump device, and a precision cable guide wheel. The vertical cable feeding servo motor is installed on the top of the vertical cable feeding guide rail. The vertical cable feeding screw is connected to the bottom of the vertical cable feeding servo motor. A vertical slider connected to the vertical cable feeding guide rail is installed on the vertical cable feeding screw. The cutter control cylinder is installed at the bottom of the vertical slider. The cutter is connected to the front end of the cutter control cylinder. A fixing frame is installed on the side of the vertical slider. The anti-jump device, the precision cable guide wheel, and the cable laying fixing clamp are installed on the fixing frame from top to bottom.

[0009] Preferably, the drive mechanism includes a right-end feed drive assembly and a left-end rotary drive assembly. The right-end feed drive assembly includes a feed-end servo motor, a feed-end synchronous pulley, a feed-end lead screw, and a feed-end transmission shaft connected in sequence. The left-end rotary drive assembly includes a rotary-end servo motor, a rotary-end synchronous pulley, and a rotary-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 rotary drive assembly by grommets, and a core through slot is formed at the upper end of the left umbrella mold; the right umbrella mold assembly includes a main shaft flange, a split core, an inlet lead wire clamp assembly, an outlet lead wire clamp assembly, a winding scale disc, and a counterweight; the main shaft flange located at the rear end of the right umbrella mold assembly is fixed to the front end of the feed end drive shaft by grommets, and the front end of the main shaft flange is connected to the split core, which is in contact with the left umbrella mold; the split core includes a core, a core clamping block, and a guide plate. The core clamping block is installed at the lower end of the core. The guide plate is fastened inside the spindle flange and located at the front end of the core clamping block and the core. A lead wire groove is opened at the upper end of the guide plate to fix the lead wire and constrain the wire to wind around the split core. The inner ring of the spindle flange is connected in series with the split core and the feed end drive shaft of the right end feed drive assembly by key pins. The cylindrical surface of the spindle flange is covered with holes. The scale disc is installed at the front end of the guide plate to accurately confirm the position of the lead wire and determine the number of turns. The lead wire inlet clamp assembly, the lead wire outlet clamp assembly and the counterweight are all installed on the outer side of the bottom of the scale disc.

[0011] Preferably, the external action mechanism includes an action cylinder, a top-in wire clamp, and a top-out wire clamp. The top-in wire clamp and the top-out wire clamp are arranged in concentric circles. The action cylinder is installed below the top-in wire clamp and the top-out wire clamp. The action cylinder, the top-in wire clamp, and the top-out wire clamp are connected by a wire clamping plate support. The wire clamping plate support is fastened to the inner wall of the saddle base by mounting blocks and bolts.

[0012] Preferably, the heating mechanism includes a hot air gun propulsion assembly and a hot air gun, the hot air gun being mounted on the hot air gun propulsion assembly, and the hot air gun propulsion assembly being close to the saddle base.

[0013] Preferably, the flipping material handling mechanism includes a finished product transfer assembly, a support traverse assembly, and a flipping wire clamp assembly. The flipping wire clamp assembly includes a core, a stripping plate, and inlet / outlet lead wire transfer clamps. The flipping wire clamp assembly is installed at one end of the support traverse assembly near the saddle base for completing the handover and transfer of coils. The finished product transfer assembly is installed at one end of the support traverse assembly away from the saddle base for finished product transfer and unloading. The support traverse assembly is installed on the machine platform.

[0014] Preferably, the cable management mechanism includes a cable management platform located at the center, and an inlet wire angle clamp and an outlet wire angle clamp are provided on the outer side of the cable management platform. The bottom of the inlet wire angle clamp and the outlet wire angle clamp are respectively connected to a cable management motor via gears; and micrometers are provided at both ends of the cable management platform.

[0015] The present invention also provides a winding method for a high-precision copper wire coil mechanical winding forming device, comprising the following steps:

[0016] S1, Servo tensioner wire feeding;

[0017] The wire enters the wire laying mechanism downwards via a servo tensioner on the wire feeding mechanism;

[0018] S2. The wire enters the cable fixing clamp;

[0019] The cable passes through the anti-jump device of the cable routing mechanism and enters the three precision cable guide rollers below, and is then clamped by the cable fixing clamp below;

[0020] S3, Prepare for winding;

[0021] The cylinder on the external action mechanism extends and raises the top wire clamping ring, opening the wire inlet clamp assembly on the winding mechanism. The vertical slider on the vertical wire feeding assembly at the front end of the wire laying mechanism extends downward, cooperating with the transverse movement assembly to move laterally. The wire laying fixing clamp feeds the wire into the wire inlet clamp assembly in the winding mechanism. The top wire clamping ring descends, and the wire inlet clamp assembly closes and clamps the wire. The wire laying 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 extends forward in cooperation, and the left umbrella mold and right umbrella mold assemblies close.

[0022] S4, Begin winding;

[0023] The left-end rotary drive component of the drive mechanism drives the rotary end transmission shaft to rotate at high speed, while the right-end feed drive component drives the feed end transmission shaft to feed slowly. The coil is wound around the split mold core. After the set number of turns is wound, the lead wire is fed into the lead wire clamp assembly at a fixed angle by the wire laying clamp. The lead wire clamp assembly closes. The hot air gun push component in the heating mechanism pushes the hot air gun into the winding working area. The winding mechanism rotates, the hot air gun heats up, melts the surface of the wire, and shapes the wire.

[0024] S5, Flip to pick up material;

[0025] The mold opens, the flipping clamp assembly moves horizontally, the front end picks up the material, the core of the flipping clamp assembly is taken out to form the coil, the external inlet and outlet lead wire transfer clamps clamp the inlet and outlet leads, the inlet lead wire clamp assembly and outlet lead wire clamp assembly in the right umbrella mold assembly release the leads, the flipping clamp assembly moves out of the saddle base and flips 90 degrees vertically, so that the coil is downward and moved to the top of the wire management platform;

[0026] S6. Adjust the lead wire angle;

[0027] The lead wire inlet and lead wire outlet angle clamps in the wire management mechanism open. The lead wire inlet and lead wire outlet transfer clamps in the flip clamp assembly transfer the lead wires to the lead wire inlet and lead wire outlet angle clamps. The stripper plate in the flip clamp assembly removes the shaped coil from the core and places it on the wire management platform. The lead wire inlet and lead wire outlet angle clamps close. Two wire management motors drive the lead wire inlet and lead wire outlet angle clamps to rotate around the wire management platform at a set angle, pulling the lead wires to complete the angle fixing of the lead wire inlet and lead wire outlet heads, and the wire management ends.

[0028] S7. Finished product transfer and unloading;

[0029] The finished product transfer component in the flipping material handling mechanism removes the finished product from the line sorting platform and transfers it to the back-end station.

[0030] Therefore, the high-precision copper wire coil mechanical winding forming device and winding method of the present invention can meet the production needs of large-volume and stable quality, reduce production costs and labor costs, improve product consistency and reliability due to the reduction of human interference, and also have high flexibility and scalability, and can be quickly adjusted and optimized according to market demand.

[0031] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the back structure of an embodiment of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0033] Figure 2 This is a schematic diagram of the wire feeding mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0034] Figure 3 This is a schematic diagram of the wire laying mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0035] Figure 4 This is a schematic diagram of the transverse movement component of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0036] Figure 5 This is a schematic diagram of the vertical wire feeding assembly of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0037] Figure 6 This is a schematic diagram of the drive mechanism of a high-precision copper wire coil mechanical winding forming device according to the present invention;

[0038] Figure 7This is a schematic diagram of the right-end feed drive assembly of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0039] Figure 8 This is a schematic diagram of the left-end rotation drive assembly of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0040] Figure 9 This is a schematic diagram of the winding mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0041] Figure 10 This is a schematic diagram of the external working mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0042] Figure 11 This is a schematic diagram of the heating mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0043] Figure 12 This is a schematic diagram of the flipping and picking mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0044] Figure 13 This is a schematic diagram of the flipping clamp assembly of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0045] Figure 14 This is a schematic diagram of the wire management mechanism of a high-precision copper wire coil mechanical winding forming device of the present invention;

[0046] Figure 15 This is a schematic diagram of the right umbrella mold assembly of a high-precision copper wire coil mechanical winding forming device of the present invention.

[0047] Figure Labels

[0048] 1. Wire feeding mechanism; 2. Wire laying mechanism; 3. Drive mechanism; 4. Winding mechanism; 5. External action mechanism; 6. Heating mechanism; 7. Tilting and picking mechanism; 8. Wire sorting mechanism; 9. Machine base; 10. Saddle base; 2-1. Servo tensioner; 2-2. Tensioner support assembly; 3-1. Lateral movement assembly; 3-1-1. Wire laying lateral movement servo motor; 3-1-2. Wire laying lateral movement module; 3-2. Vertical wire feeding assembly; 3-2-1. Vertical wire feeding servo motor 3-2-2, Vertical wire feed screw; 3-2-3, Vertical wire feed guide rail; 3-2-4, Cutter; 3-2-5, Wire clamp for fixing wire; 3-2-6, Cutter control cylinder; 3-2-7, Anti-jump device; 3-2-8, Precision wire guide 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; 4-1-4, Feed end drive shaft; 4-2, Left end rotary screw... 4-2-1 Rotary end servo motor; 4-2-2 Rotary end synchronous pulley; 4-2-3 Rotary end drive shaft; 5-1 Left umbrella mold; 5-2 Right umbrella mold assembly; 6-1 Top infeed clamping ring; 6-2 Top outfeed clamping ring; 6-3 Actuating cylinder; 6-4 Wire clamping disc support seat; 6-5 Mounting fixing block; 7-1 Hot air gun propulsion assembly; 7-2 Hot air gun; 8-1 Finished product transfer assembly; 8-2 Support transverse movement assembly Components; 8-3, Flip-over wire clamp assembly; 8-3-1, Core; 8-3-2, Inlet / outlet lead wire transfer clamp; 9-1, Wire management platform; 9-2, Inlet lead wire angle clamp assembly; 9-3, Outlet lead wire angle clamp assembly; 9-4, Servo motor; 9-5, Gear; 11-1, Main spindle flange; 11-2, Split mold core; 11-3, Inlet lead wire clamp assembly; 11-4, Outlet lead wire clamp assembly; 11-5, Counterweight; 11-6, Winding scale disc. Detailed Implementation

[0049] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0050] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0051] Example 1

[0052] As shown in the figure, the present invention provides a high-precision copper wire coil mechanical winding forming device, including a machine base 9, on which a saddle base 10 is installed at the front end. A wire feeding mechanism 1 fixed on the machine base 9 is installed on the left side of the saddle base 10 to control the wire to enter the wire laying mechanism 2 installed on its right side. The wire laying mechanism 2 is installed on the left end platform of the saddle base 10. A drive mechanism 3 fixed in the saddle base 10 is provided at the lower end of the wire laying mechanism 2. The drive mechanism 3 passes through the saddle base 10 to drive the winding mechanism 4 to wind the wire. The winding mechanism 4 is fixed at the front end of the drive mechanism 3 and located at the center position of the saddle base 10.

[0053] An external action mechanism 5 is installed on the inner wall of the right end of the saddle base 10, located to the right of the winding mechanism 4. A heating mechanism 6 is installed at the bottom of the saddle base 10 for heat-melting and shaping the outer surface of the wire. A flipping and picking mechanism 7 is installed on the platform at the right end of the saddle base 10 for transferring the wound coil to the wire sorting mechanism 8. The wire sorting mechanism 8 is installed on the machine base 9 and located at the rear end of the saddle base 10.

[0054] The wire feeding mechanism 1 includes a servo tensioner 2-1 and a tensioner support assembly 2-2. The wire feeding mechanism 1 is installed on the upper part of the machine base 9. The bottom of the tensioner support assembly 2-2 is fixed to the machine base 9 by bolts. 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 tension 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.

[0055] The wire laying mechanism 2 is installed on the left end platform of the saddle base 10 for vertical wire laying, located at the right end of the wire feeding mechanism 1. The wire laying mechanism 2 includes a horizontal moving component 3-1 and a vertical wire feeding component 3-2. The horizontal moving component 3-1 includes a wire laying horizontal moving servo motor 3-1-1 and a wire laying horizontal moving module 3-1-2. The bottom of the wire laying horizontal moving module 3-1-2 is fixed to the left end platform of the saddle base 10 by bolts, controlling the horizontal movement of the wire laying mechanism 2, accurately positioning 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 horizontal movement assembly 3-1. It includes a vertical wire feeding servo motor 3-2-1, a vertical wire feeding lead screw 3-2-2, a vertical wire feeding guide rail 3-2-3, a cutter 3-2-4, a wire laying clamp 3-2-5, a cutter control cylinder 3-2-6, an anti-jump device 3-2-7, and precision wire guide rollers 3-2-8. The anti-jump device 3-2-7 and the three precision wire guide rollers 3-2-8, in conjunction with the wire laying clamp 3-2-5, ensure the stability of the wire laying. The vertical wire feeding servo motor 3-2-1 works in conjunction with the vertical wire feeding lead screw... Rod 3-2-2 and vertical wire feeding guide 3-2-3 enable longitudinal wire feeding into the wire inlet clamp assembly of winding mechanism 4. A vertical slider connected to the vertical wire feeding guide 3-2-3 is mounted on the vertical wire feeding screw 3-2-2. A cutter control cylinder 3-2-6 is installed at the bottom of the vertical slider, while a cutter 3-2-4 is connected to the front end of the cutter control cylinder 3-2-6. A mounting bracket is installed on the side of the vertical slider. An anti-jump device 3-2-7, a precision wire guide wheel 3-2-8, and a wire guide clamp 3-2-5 are sequentially mounted on the mounting bracket from top to bottom. After winding, the cutter control cylinder 3-2-6 extends, the cutter 3-2-4 cuts the wire, and the wire guide clamp 3-2-5 continues to hold the lead wire end, ensuring the continuity of winding.

[0056] The drive mechanism 3 includes a right-end feed drive assembly 4-1 and a left-end rotary drive assembly 4-2. The drive mechanism 3 is fixed in the saddle base 10, located at the lower end of the wire winding mechanism 2, and drives the winding mechanism 4 through the saddle base 10 for winding. The right-end feed drive assembly 4-1, equipped with a feed-end servo motor 4-1-1, uses a feed-end synchronous pulley 4-1-2 to drive the feed-end lead screw 4-1-3, converting the rotational motion of the feed-end drive shaft 4-1-4 into linear feed motion. This allows for simultaneous rotary feed motion. The left-end rotary drive assembly 4-2 is controlled and driven by a rotary-end servo motor 4-2-1, which, through the rotary-end synchronous pulley 4-2-2, drives the rotary-end drive shaft 4-2-3 to rotate at high speed, thus completing the precision winding.

[0057] The winding mechanism 4 is fixed to the front end of the two-end drive mechanism 3, located in 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 rotary drive assembly 4-2 by a mortise screw. During the winding process, it abuts against the right umbrella mold assembly 5-2, limiting the distance of the wire's lateral arrangement and the extent of the wound wire. The right umbrella mold assembly 5-2 includes a main shaft flange 11-1, a split mold core 11-2, an inlet lead wire clamp assembly 11-3, an outlet lead wire clamp assembly 11-4, a counterweight 11-5, and a winding scale disc 11-6. The main shaft flange 11-1, located at the tail end of the right umbrella mold assembly 5-2, is fixedly installed at the front end of the feed end drive shaft 4-1-4 by grommets. The front end of the main shaft 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 of them use special materials combined with special heat treatment and surface treatment to achieve non-stick coil layer during the winding process.

[0058] The split mold core package 11-2 includes a mold core, a mold core clamping block, and a guide plate. The mold core clamping block is installed at the lower end of the mold core. The guide plate is fastened inside the spindle flange 11-1 and located at the front end of the mold core clamping block and the mold core. A lead wire groove is opened at the upper end of the guide plate to fix the lead wire and constrain the wire to wind around the split mold core. The inner ring of the spindle flange 11-1 is connected in series with the split mold core and the feed end drive shaft 4-1-4 of the right end feed drive assembly 4-1 by key pins. The cylindrical surface of the spindle flange 11-1 is covered with holes.

[0059] The winding scale disc 11-6 is installed at the front end of the conductor plate to accurately confirm the position of the lead wire and determine the number of turns. The inlet lead wire clamp assembly 11-3, the outlet lead wire clamp assembly 11-4, and the counterweight 11-5 are all installed on the outer side of the bottom of the winding scale disc 11-6. The inlet lead wire clamp assembly 11-3 and the outlet lead wire clamp assembly 11-4 are used to fix the inlet and outlet lead wire heads during the winding process, and the counterweight 11-5 increases the weight of the winding scale disc 11-6 to ensure the stability of the high-speed rotation winding process.

[0060] The lead wire clamp assembly 11-3 includes a lead wire clamp, a termination spring pressure rod, a first termination spring pressure block, and a first clamp spring. The lead wire clamp assembly is installed at the bottom of the winding scale disc and is mounted on the extension line of the lead wire groove. The first termination spring pressure block is pressed against by the top lead wire clamp ring 6-1 in the external external action mechanism 5, which drives the termination spring pressure rod to rotate, thereby controlling the opening of the clamp. The first clamp spring controls the reset and closes the clamp.

[0061] The lead wire clamp assembly 11-4 includes a lead wire clamp base, a terminal wire clamp, a clamp shaft, a second terminal wire spring pressure block, and a second clamp spring. The lead wire clamp assembly is installed at the bottom of the winding scale disc, in the required position. The lead wire clamp ring 6-2 in the external action mechanism 5 presses against the second terminal wire spring pressure block, driving the clamp shaft to rotate, controlling the opening of the clamp. The second clamp spring controls the reset, closing the clamp.

[0062] The counterweights 11-5 are distributed at the bottom of the winding scale disc 11-6 and are installed in the other arc-shaped waist grooves except for the inlet lead clamp assembly 11-3 and the outlet lead clamp assembly 11-4. They are used to balance the center of the entire right umbrella mold assembly 5-2 and can ensure the stability of the winding.

[0063] The external action mechanism 5 is installed on the inner wall of the right end of the saddle base 10, located between the winding mechanism 4 and the right wall of the saddle base 10. The external action mechanism 5 includes a top-in clamping ring 6-1, a top-out clamping ring 6-2, and an action cylinder 6-3, all connected by a clamping disc support 6-4. The clamping disc support 6-4 is fastened to the inner wall of the saddle base 10 by mounting blocks 6-5 and bolts. The extension and retraction of the action cylinder 6-3 controls the rise and fall of the top-in clamping ring 6-1 and the top-out clamping ring 6-2, and controls the opening and closing of the inlet and outlet lead clamp assemblies in the winding mechanism 4, clamping the inlet and outlet lead heads at the beginning and end of winding.

[0064] The heating mechanism 6 is installed on the bottom side of the saddle base 10 and is used to heat melt and shape 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 obliquely upward to the winding working area to provide a sufficient temperature environment. At the same time, it can retract during the material picking process of the flipping material picking mechanism 7 to avoid interference.

[0065] The flipping and picking mechanism 7 is installed on the right platform 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 assembly 8-1, a support transverse movement module 8-2, and a flipping wire clamp assembly 8-3. The flipping wire clamp assembly 8-3 includes a core, a stripping plate, and inlet / outlet lead wire transfer clamps. It is installed on the support transverse movement assembly 8-2 near the saddle base 10. The coil transfer is completed by the transverse movement of the wire management mechanism 8 and the saddle base 10. The finished product transfer assembly 8-1 is installed on the support transverse movement assembly 8-2 away from the saddle base 10 for finished product transfer and unloading. The support transverse movement assembly 8-2 is installed on the machine base 9 to complete stable transverse movement.

[0066] The wire management mechanism 8 is installed on the machine base 9 at the rear end of the saddle base 10. It shapes the lead ends of the coil. Once the shaping is successful, it becomes the finished coil. The wire management mechanism 8 includes a wire management platform located at the center. The outer side of the wire management platform is equipped with lead-in angle clamps and lead-out angle clamps. The bottom of the lead-in angle clamps and lead-out angle clamps are respectively connected to wire management motors via gears. Micrometers are provided at both ends of the wire management platform.

[0067] The core structure of the wire management mechanism 8 lies in the coordinated action of the wire management platform 9-1 with the lead wire infeed angle clamp 9-2 and the lead wire outfeed angle clamp 9-3. Two wire management motors mounted at the bottom, via gear transmission, drive the lead wire infeed angle clamp 9-2 and the lead wire outfeed angle clamp 9-3 to rotate around the central wire management platform 9-1. Simultaneously, micrometers at both ends of the wire management platform 9-1 adjust its position. The wire management mechanism 8 prevents the enameled wire from crossing or tangling, ensuring that each turn of enameled wire is accurately wound in the predetermined position, guaranteeing the quality and performance of the coil. The wire management mechanism 8 can also adjust the tension in real time, maintaining it within a suitable range to ensure the tightness and uniformity of the winding.

[0068] The present invention also provides a winding method for a high-precision copper wire coil mechanical winding forming device, comprising the following steps:

[0069] S1, Servo tensioner 2-1 for wire feeding;

[0070] The wire enters the cable laying mechanism 2 downwards through the servo tensioner 2-1 on the cable laying mechanism 1.

[0071] S2, The wire enters the cable fixing clamp 3-2-5;

[0072] The cable passes through the anti-jump device 3-2-7 of the cable routing mechanism 2 and enters the three precision cable guide rollers 3-2-8 below, and is then clamped by the cable fixing clamp 3-2-5 below.

[0073] S3, Prepare for winding;

[0074] The cylinder 6-3 on the external action mechanism 5 extends and the top wire clamping ring 6-1 rises, opening the wire inlet clamp assembly 11-3 on the winding mechanism 4. The vertical slider on the vertical wire feeding assembly 3-2 at the front end of the wire laying mechanism 2 extends downward and moves laterally in conjunction with the transverse movement assembly 3-1. The wire laying fixing clamp 3-2-5 feeds the wire into the wire inlet clamp assembly 11-3 in the winding mechanism 4. The top wire clamping ring 6-1 descends, and the wire inlet clamp assembly 11-3 clamps the wire. The wire laying mechanism 2 then 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. The right end feed drive assembly 4-1 in the drive mechanism 3 extends forward in coordination, and the left umbrella mold 5-1 and the right umbrella mold assembly 5-2 close.

[0075] S4, Begin winding;

[0076] The left end rotation drive component 4-2 of the drive mechanism 3 drives the rotating end transmission shaft 4-2-3 to rotate at high speed, while the right end feed drive component 4-1 drives the feed end transmission shaft 4-1-4 to move slowly. The coil is wound around the split mold core 11-2. After the set number of turns are wound, the lead wire is fed into the lead wire clamp component 11-4 at a fixed angle by the wire fixing clamp 3-2-5. The lead wire clamp component 11-4 closes. The hot air gun push 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 heats up the wire, melting the surface of the wire and shaping the wire.

[0077] S5, Flip to pick up material;

[0078] The mold opens, the flip-over clamp assembly 8-3 moves horizontally, the front end picks up the material, the core 8-3-1 of the flip-over clamp assembly 8-3 takes out the shaped coil, the external inlet and outlet lead wire transfer clamp 8-3-2 clamps the inlet and outlet leads, the inlet lead wire clamp assembly 11-3 and outlet lead wire clamp assembly 11-4 in the right umbrella mold assembly 5-2 release the leads, the flip-over clamp assembly 8-3 moves out of the saddle base 10 and flips 90 degrees vertically, so that the coil is downward and moved to the top of the wire management platform.

[0079] S6. Adjust the lead wire angle;

[0080] In the wire management mechanism 8, the lead wire angle clamp 9-2 and the lead wire angle clamp 9-3 open. The lead wire transfer clamp 8-3-2 of the flip clamp assembly 8-3 transfers the lead wires to the lead wire angle clamp 9-2 and the lead wire angle clamp 9-3. The stripping plate in the flip clamp assembly 8-3 removes the shaped coil from the core 8-3-1 and places it on the wire management platform 9-1. The lead wire angle clamp 0-2 and the lead wire angle clamp 9-3 close. Two wire management motors drive the lead wire angle clamps 9-5 and 9-5, the lead wire angle clamps 9-3 and 9-4 to rotate around the wire management platform 9-1 at a set angle, pulling the lead wires to complete the angle fixing of the lead wire head, and the wire management ends.

[0081] S7. Finished product transfer and unloading;

[0082] The finished product transfer component 8-1 in the flipping material handling mechanism 7 takes the finished product out of the line level 9-1 and transfers it to the back-end station.

[0083] Therefore, the present invention employs the above-mentioned high-precision copper wire coil mechanical winding forming device and winding method, which can meet the production needs of large-volume and stable quality, reduce production costs and labor costs, improve product consistency and reliability due to the reduction of human interference, and also has high flexibility and scalability, and can be quickly adjusted and optimized according to market demand.

[0084] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. A high-precision copper wire coil mechanical winding forming device, characterized in that: The device includes a machine base with a saddle base at its front end. A wire feeding mechanism, fixed to the machine base, is mounted on the left side of the saddle base to control the wire entering a winding mechanism mounted on its right side. The winding mechanism is mounted on a platform at the left end of the saddle base. A drive mechanism, fixed within the saddle base, is located at the lower end of the winding mechanism. This drive mechanism passes through the saddle base to drive the winding mechanism for winding. The winding mechanism is fixed at the front end of the drive mechanism, located at the center of the saddle base. An external action mechanism is mounted on the inner wall of the right end of the saddle base, located to the right of the winding mechanism. A heating mechanism is mounted at the bottom of the saddle base for heat-melting and shaping the outer surface of the wire. A flipping and picking mechanism is mounted on the platform at the right end of the saddle base to transfer the wound coil to a wire management mechanism, which is mounted on the machine base and located at the rear end of the saddle base. The drive mechanism includes a right-end feed drive assembly and a left-end rotary drive assembly. The right-end feed drive assembly includes a feed-end servo motor, a feed-end synchronous pulley, a feed-end lead screw, and a feed-end transmission shaft connected in sequence. The left-end rotary drive assembly includes a rotary-end servo motor, a rotary-end synchronous pulley, and a rotary-end transmission shaft connected in sequence. 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 rotary drive assembly by grommets, and a core through slot is formed on the upper end of the left umbrella mold. The right umbrella mold assembly includes a main shaft flange, a split core, an inlet lead wire clamp assembly, an outlet lead wire clamp assembly, a winding scale disc, and a counterweight. The main shaft flange located at the rear end of the right umbrella mold assembly is fixed to the front end of the feed drive shaft by grommets. The front end of the main shaft flange is connected to the split core, and the split core is in contact with the left umbrella mold. The split core includes a core, a core clamping block, and a guide plate. The core clamping block is installed at the lower end of the core. The guide plate is fastened inside the spindle flange and located at the front end of the core clamping block and the core. A lead wire groove is opened at the upper end of the guide plate to constrain the wire winding around the split core. The inner ring of the spindle flange is connected in series with the split core and the feed end drive shaft of the right end feed drive assembly by key pins. The cylindrical surface of the spindle flange is covered with holes. The scale disc is installed at the front end of the guide plate to accurately confirm the lead wire position and determine the number of turns. The inlet lead wire clamp assembly, the outlet lead wire clamp assembly and the counterweight are all installed on the outer side of the bottom of the scale disc.

2. The high-precision copper wire coil mechanical winding forming device according to claim 1, characterized in that: The wire feeding mechanism includes a servo tensioner and a tensioner support assembly. The bottom of the tensioner support assembly is fixed to the machine base 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, characterized in that: The cable laying mechanism includes a horizontal movement component and a vertical cable feeding component. The horizontal movement component includes a cable laying horizontal movement servo motor and a cable laying horizontal movement module. The bottom of the cable laying horizontal movement servo motor is fixed to the left end platform of the saddle base by bolts. The vertical cable feeding component is mounted on the cable laying horizontal movement module and includes a vertical cable feeding servo motor, a vertical cable feeding lead screw, a vertical cable feeding guide rail, a cutter, a cable laying fixing clamp, a cutter control cylinder, an anti-jump device, and a precision cable guide wheel. The vertical cable feeding servo motor is mounted on the top of the vertical cable feeding guide rail, the vertical cable feeding lead screw is connected to the bottom of the vertical cable feeding servo motor, and a vertical slider connected to the vertical cable feeding guide rail is mounted on the vertical cable feeding lead screw. The cutter control cylinder is mounted on the bottom of the vertical slider, and the cutter is connected to the front end of the cutter control cylinder. A fixing frame is mounted on the side of the vertical slider, and the anti-jump device, the precision cable guide wheel, and the cable laying fixing clamp are mounted on the fixing frame from top to bottom.

4. The high-precision copper wire coil mechanical winding forming device according to claim 1, characterized in that: The external action mechanism includes an action cylinder, a top inlet clamp, and a top outlet clamp. The top inlet clamp and the top outlet clamp are arranged in concentric circles. The action cylinder is installed below the top inlet clamp and the top outlet clamp. The action cylinder, the top inlet clamp, and the top outlet clamp are connected by a clamping plate support. The clamping plate support is fastened to the inner wall of the saddle base by mounting blocks and bolts.

5. The high-precision copper wire coil mechanical winding forming device according to claim 1, characterized in that: The heating mechanism includes a hot air gun propulsion assembly and a hot air gun, the hot air gun being mounted on the hot air gun propulsion assembly, which is located close to the saddle base.

6. 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 lateral movement assembly, and a flipping wire clamp assembly. The flipping wire clamp assembly includes a core, a stripping plate, and inlet / outlet lead wire transfer clamps. The flipping wire clamp assembly is installed at one end of the support lateral movement assembly near the saddle base and is used to complete the handover and transfer of coils. The finished product transfer assembly is installed at one end of the support lateral movement assembly away from the saddle base and is used for finished product transfer and unloading. The support transverse movement assembly is mounted on the machine base.

7. The high-precision copper wire coil mechanical winding forming device according to claim 1, characterized in that: The cable management mechanism includes a cable management platform located at the center, and an inlet wire angle clamp and an outlet wire angle clamp are provided on the outer side of the cable management platform. The bottom of the inlet wire angle clamp and the outlet wire angle clamp are respectively connected to a cable management motor via gears; a micrometer is provided at both ends of the cable management platform.

8. A winding method for a high-precision copper wire coil mechanical winding forming device as described in any one of claims 1-7, characterized in that, Includes the following steps: S1, Servo tensioner wire feeding; The wire enters the wire laying mechanism downwards via a servo tensioner on the wire feeding mechanism; S2. The wire enters the cable fixing clamp; The cable passes through the anti-jump device of the cable routing mechanism and enters the three precision cable guide rollers below, and is then clamped by the cable fixing clamp below; S3, Prepare for winding; The cylinder on the external action mechanism extends, the top wire clamping ring rises, the wire inlet clamp assembly on the winding mechanism opens, the vertical slider on the vertical wire feeding assembly at the front end of the wire laying mechanism extends downward, and moves laterally in conjunction with the transverse moving assembly. The wire laying fixing clamp feeds the wire into the wire inlet clamp assembly in the winding mechanism, the top wire clamping ring descends, the wire inlet clamp assembly closes and clamps the wire, and the wire laying 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 extends forward in coordination, and the left umbrella mold and right umbrella mold assemblies close. S4, Begin winding; The left end rotation drive component of the drive mechanism drives the transmission shaft to rotate at high speed, while the right end feed drive component drives the transmission shaft to feed slowly. The coil is wound around the split mold core. After the set number of turns is wound, the lead wire is fed into the lead wire clamp assembly at a fixed angle by the wire laying clamp. The lead wire clamp assembly closes. The hot air gun push component in the heating mechanism pushes the hot air gun into the winding working area. The winding mechanism rotates, the hot air gun heats up, melts the surface of the wire, and shapes the wire. S5, Flip to pick up material; The mold opens, the flipping clamp assembly moves horizontally, the front end picks up the material, the core of the flipping clamp assembly is taken out to form the coil, the external inlet and outlet lead wire transfer clamps clamp the inlet and outlet leads, the inlet lead wire clamp assembly and outlet lead wire clamp assembly in the right umbrella mold assembly release the leads, the flipping clamp assembly moves out of the saddle base and flips 90 degrees vertically, so that the coil is downward and moved to the top of the wire management platform; S6. Adjust the lead wire angle; The lead wire inlet and lead wire outlet angle clamps in the wire management mechanism open. The lead wire inlet and lead wire outlet transfer clamps in the flip clamp assembly transfer the lead wires to the lead wire inlet and lead wire outlet angle clamps. The stripper plate in the flip clamp assembly removes the shaped coil from the core and places it on the wire management platform. The lead wire inlet and lead wire outlet angle clamps close. Two wire management motors drive the lead wire inlet and lead wire outlet angle clamps to rotate around the wire management platform at a set angle, pulling the lead wires to complete the angle fixing of the lead wire inlet and lead wire outlet heads, and the wire management ends. S7. Finished product transfer and unloading; The finished product transfer component in the flipping material handling mechanism removes the finished product from the line sorting platform and transfers it to the back-end station.

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