A core roll forming device and forming process

Abstract

The present invention provides an iron core roll forming device and forming process, which relates to the field of transformer manufacturing technology, including: a base; an operating vertical plate is vertically provided on the upper end of the base; a controller and a laser welding machine are fixedly mounted on the operating vertical plate; a material rack for storing ungrooved iron sheets is rotatably provided at one end of the operating vertical plate, and a roller for winding the slotted iron sheets is provided at the other end of the operating vertical plate; a stamping mechanism and a cutting mechanism are provided on the operating vertical plate between the material rack and the roller. The present invention realizes the automation of the entire process of iron core rolls from grooving, winding, thickness monitoring, cutting to welding through the mechanical linkage and coordination of electric control signals of the stamping mechanism, the winding drive mechanism, the correction mechanism and the spot welding mechanism. The integrated stamping-cutting-winding processing method can avoid the problems in the prior art of pre-grooving an excessive amount of iron sheet coils before winding, which occupies too much space and the problem that the coils are easily damaged by bending due to the grooving.

Description

Technical Field

[0001] The present invention relates to the technical field of transformer manufacturing, and in particular to an iron core roll forming device and a forming process. Background Art

[0002] As the core component of electromagnetic equipment, the efficiency and quality of the forming process of the iron core roll directly affect the product performance. The traditional manufacturing process usually adopts a step-by-step operation mode: first, the iron sheets are slotted in batches through independent stamping equipment, and then the slotted iron sheets are transferred to the winding station for manual or semi-automatic winding. This process has significant defects: First, the pre-slotted iron sheets are prone to bending and deformation or surface scratches due to the slot structure during storage and transportation, resulting in misalignment or loose fitting between layers during winding; second, the step-by-step operation requires a large amount of space for temporary storage of semi-finished products, and the process connection relies on manual intervention, which is inefficient and difficult to ensure consistency. In addition, traditional winding equipment lacks a dynamic correction mechanism. The edges of the iron sheets are easily offset during continuous winding, resulting in the accumulation of gaps between the layers of the iron core roll. The density decreases with increasing thickness, affecting the magnetic circuit performance.

[0003] Existing technologies for fracture welding often rely on manual positioning or fixed welding guns, which can lead to inaccurate welding timing and large positioning deviations. This results in insufficient fracture joint strength and is prone to cracking during subsequent processing. Furthermore, the drive systems of the stamping and winding equipment are often independently controlled, making it difficult to achieve strict synchronization between the slot spacing and the winding pitch. This speed difference can easily lead to tensile deformation of the iron sheet or slot misalignment defects. Summary of the Invention

[0004] The present invention relates to an iron core roll forming device and forming process, which realizes the full process automation of "winding-monitoring-cutting-welding" through the precise coordination of mechanical linkage and electrical control signals, and significantly improves the efficiency and consistency of iron core roll forming.

[0005] The present invention provides an iron core roll forming device and forming process, which specifically comprises: a base; an operating vertical plate is vertically provided on the upper end of the base; a controller and a laser welding machine are fixedly mounted on the operating vertical plate; a material rack for storing unslotted iron sheets is rotatably provided at one end of the operating vertical plate, and a winding roller for winding the slotted iron sheets is provided at the other end of the operating vertical plate; a stamping mechanism and a cutting mechanism are provided on the operating vertical plate between the material rack and the winding roller, the stamping mechanism is close to the material rack, and the cutting mechanism is close to the winding roller; the stamping mechanism is composed of a stamping frame and a stamping table, and the stamping frame is located above the stamping table; the cutting mechanism is composed of a cutting frame and a cutting guide The cutting frame is located above the cutting guide table; a forming pressure column is fixed vertically and horizontally on the operating vertical plate just above the winding roller, and a movable hole is vertically provided on the operating vertical plate where the winding roller is located, and the winding roller can move vertically in the movable hole; a correction mechanism is vertically provided on the forming pressure column, and a spot welding mechanism is provided on the correction mechanism and inserted into the forming pressure column; the correction mechanism is composed of a gantry structure composed of a counterweight cross bar and a correction guide rod, which is used to ensure that the iron core roll is neat during the forming process; the spot welding mechanism is composed of an adjusting screw, a spot welding frame, a ruler and a welding contact seat, which spot welds the fracture after a roll of iron core is wound and formed.

[0006] Optionally, two layers of pressure rods are vertically provided on the operating vertical plate between the material rack and the punching table. The unslotted iron sheet passes through the upper and lower pressure rods, and the upper pressure rod is offset against the material rack to press the material line of the unslotted iron sheet.

[0007] Optionally, the upper end of the punching frame is a vertical punching cylinder, the piston rod of the punching cylinder is fixedly connected downward to a punching die head, and the punching die head moves downward to slot the iron sheet passing below.

[0008] Optionally, a discharge hole corresponding to the vertical direction of the stamping die head is vertically opened in the stamping table, and the stamping table at the lower end of the discharge hole is an outward and downward beveled structure.

[0009] Optionally, the middle part of the upper end of the cutting frame is a vertical cutting cylinder, the end of the piston rod of the cutting cylinder is fixedly connected vertically downward with a cutter, and the cutter moves down to the cutting guide to cut off the iron sheet after the slotting.

[0010] Optionally, the upper end surface of the punching platform, the upper end surface of the cutting guide platform and the lower end of the forming pressure column are always on the same horizontal plane.

[0011] Optionally, the winding roller rotates on the rotating shaft at one end close to the operating vertical plate, and the sleeve block slides vertically and is clamped in the movable hole. The sleeve block is fixed with a forming motor at the end away from the winding roller to drive the winding roller to rotate. A suspension rod is vertically provided at the upper end of the sleeve block, and the upper end of the suspension rod slides vertically through the fixed plate. The fixed plate is fixedly connected to the operating vertical plate. A baffle is provided at the end of the suspension rod. A first spring is mounted on the suspension rod between the baffle and the fixed plate. The first spring provides an upward pulling force for the sleeve block part. The forming motor drives the winding roller to rotate at an angle consistent with the slot spacing of the iron sheet. The stamping cylinder punches once, and the forming motor winds one unit.

[0012] Optionally, annular alignment ring grooves are respectively provided on the roller surfaces at both ends of the winding roller, and correction guide rods are respectively provided for vertical sliding at positions at both ends of the forming pressure column corresponding vertically to the alignment ring grooves. The lower end of the correction guide rod is a ball-shaped structure, and the lower end of the correction guide rod is always slid and placed in the corresponding alignment ring groove. A counterweight cross bar is provided between the upper ends of the two correction guide rods, and the upper end of the correction guide rod and the counterweight cross bar are connected by a vertical rotation shaft. The slotted iron sheet is wound on the winding roller between the two alignment ring grooves, and the correction guide rod is tangent to the edge of the wound iron sheet. As the number of wound iron sheets increases, the winding roller moves downward, the first spring is compressed, and the extrusion force between the iron sheet on the winding roller and the forming pressure column increases, and the iron sheet at the bottom of the forming pressure column always maintains the same height to keep the winding stable.

[0013] Optionally, the middle part of the upper end of the counterweight cross bar is connected to the adjusting screw for vertical rotation, and the counterweight cross bar on one side of the adjusting screw is a vertically upward scale. The middle part of the gantry-shaped spot welding frame is screwed to the adjusting screw for rotation, and the upper end of the scale slides vertically through the spot welding frame, and the lower end of the scale is the scale zero point. The two ends of the spot welding frame pass through the counterweight cross bar vertically downward and pass through the forming pressure column below. A table groove is provided on the side of the cutting frame at the lower end of the spot welding frame, and a "T"-shaped welding contact seat is vertically slidably provided in the table groove. Two symmetrical insertion rods are vertically provided at the upper end of the welding contact seat, and a second spring is installed on the insertion rod. The insertion rod is vertically slid and inserted into the top of the table groove. Limiting columns are vertically symmetrically provided at the position near the lower end of the table groove. The limiting columns are used to stop the welding contact seat to prevent the welding contact seat from moving down and dislocating. A pressure sensor is provided at the bottom of the welding contact seat. A laser welding head is provided on the side of the welding contact seat away from the cutting frame, which is inclined downward. The laser welding head is connected to the laser welding machine, and the screw is adjusted to adjust the height of the spot welding frame, that is, the windable thickness of the iron sheet on the roller. The roller is forced to move downward during the process of thickening the iron sheet. The correction structure and the cutting mechanism move downward synchronously under the action of their own gravity until the welding contact seat moves down and passes through the bottom of the forming pressure column to contact the iron sheet. The pressure sensor sends a signal, the stamping cylinder stops working, the cutting cylinder starts working, the forming motor rotates continuously, the laser welding head is preheated and started, and when the lower end of the welding contact seat contacts the cut-off fracture, the welding contact seat moves down by the thickness of an iron sheet, the signal of the pressure sensor changes suddenly, the forming motor stops working, and the laser welding head starts to weld the iron sheet fracture synchronously, and the iron core roll is formed.

[0014] A forming process of an iron core roll forming device comprises the following steps:

[0015] S1. Loading and Positioning: Install the unslotted iron sheet coil on the material rack. Pull the free end of the iron sheet through the gap between the pressure rods, the surface of the punching table, and the surface of the cutting guide, and securely wrap it between the alignment ring grooves of the winding roller.

[0016] S2. Parameter setting: Adjust the height of the spot welding frame by rotating the adjustment screw so that the scale indicates the preset core coil thickness threshold and set the welding parameters of the laser welding machine;

[0017] S3.Continuous molding:

[0018] a. Start the stamping cylinder and forming motor. The stamping die periodically slots the passing iron sheet. The forming motor synchronously drives the winding roller to rotate the coil at an angular velocity that matches the slot spacing.

[0019] b. During the winding process of the slotted iron sheet, the ball end of the correction guide rod slides along the alignment ring groove, forcing the edges of the coil layer to align; as the coil thickness increases, the coil roller presses down to compress the first spring, and the forming pressure column continues to apply downward pressure to maintain the density of the coil layer;

[0020] S4. Thickness Monitoring and Cutting: When the coil thickness reaches the threshold, the weld contact seat contacts the surface of the iron sheet, triggering the pressure sensor. The controller immediately stops the punching cylinder and activates the cutting cylinder to cut the iron sheet. At the same time, the forming motor keeps running to pull the cutting edge forward.

[0021] S5. Fracture welding: When the fracture moves to the bottom of the welding contact seat, the downward movement of the iron sheet triggers a sudden change in the pressure signal. The controller synchronously stops the forming motor and activates the laser welding head to perform spot welding on the fracture to complete the core roll forming.

[0022] The present invention provides an iron core roll forming device and forming process, which has the following beneficial effects:

[0023] 1. The present invention realizes the automation of the entire process of iron core coil from slotting, winding, thickness monitoring, cutting to welding through the mechanical linkage and coordination of electric control signals of the stamping mechanism, winding drive mechanism, correction mechanism and spot welding mechanism. The cooperation between the pressure sensor and the controller realizes the real-time monitoring of the coil thickness threshold and the switching of processing status (such as stamping stop, cutting trigger, welding start), which significantly reduces manual intervention and improves production efficiency and process consistency. The integrated stamping-cutting-winding processing method can avoid the problems of the existing technology of pre-slotting too many iron sheet coils and then winding them, which takes up too much space and the coils are easily damaged by bending due to slotting.

[0024] 2. This invention utilizes the sliding fit of the correction guide rod and the alignment grooves at both ends of the winding roller, combined with the downward pressure of the counterweight crossbar, to continuously constrain the edge alignment of the iron sheets during the winding process, ensuring no misalignment between layers. The elastic suspension design of the winding roller (the first spring) and the constant pressure of the forming pressure column ensure that the iron sheets are always under uniform pressure during the winding process. The density of the iron core coil increases adaptively with thickness, avoiding the looseness caused by gaps between layers in traditional processes.

[0025] 3. This invention utilizes the floating structure of the welding contact seat (second spring and limit pin) and the pressure sensor trigger mechanism, combined with the continuous traction of the forming motor, to ensure that the cut end automatically moves to the welding station after cutting. The tilted design of the laser welding head utilizes winding tension to ensure a tight fit of the cut end. Combined with the instantaneous welding triggered by a sudden change in the pressure signal, this solves the problem of insufficient weld strength caused by positioning deviation in traditional spot welding, significantly improving welding accuracy and reliability.

[0026] 4. The oblique discharge hole design of the punching table in the present invention realizes the rapid and automatic discharge of the punching waste, avoiding the risk of blockage; the strict synchronous control of the punching cylinder and the forming motor (one punching corresponds to one winding unit) ensures that the slot spacing and the winding pitch are accurately matched, eliminating the tensile deformation of the iron sheet or the slotting dislocation defects caused by the speed asynchrony in traditional step-by-step processing.

[0027] 5. The coordination of the adjustment screw and scale in this invention allows for preset thickness thresholds for different core roll sizes through simple operations, adapting to diverse production needs. The follow-up downward movement design of the correction mechanism and spot welding mechanism (based on the downward pressure of the roll and the action of gravity) allows the equipment to automatically maintain the relative position of the functional modules during changes in roll thickness, ensuring process stability while reducing the complexity of equipment commissioning. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings of the embodiments are briefly introduced below.

[0029] The drawings described below only relate to some embodiments of the present invention, but are not intended to limit the present invention.

[0030] In the attached figure:

[0031] Figure 1 shows a schematic diagram of the first axial view of the present invention;

[0032] Figure 2 shows a second axial structural schematic diagram of the present invention;

[0033] Figure 3 shows a schematic structural diagram of the third axis view of the present invention;

[0034] Figure 4 It shows an axial structural schematic diagram of the forming pressure column of the present invention in an upwardly moving and separated state;

[0035] Figure 5 It shows a schematic diagram of the axial structure of the forming pressure column of the present invention in a half-cut and separated state;

[0036] Figure 6 It shows an axial structural schematic diagram of the present invention in a state where the correction mechanism and the spot welding mechanism are separated;

[0037] Figure 7 It shows a schematic diagram of the axial structure of the spot welding mechanism of the present invention in a partially disassembled state;

[0038] Figure 8 The present invention shows Figure 7 A in the middle is a schematic diagram of the structure of the enlarged part;

[0039] Figure 9 The figure shows the axial structural schematic diagram of the iron core coil taken out state of the present invention.

[0040] Reference numerals

[0041] 1. Base;

[0042] 2. Operation vertical plate; 201. Movable hole; 202. Press rod;

[0043] 3. Controller;

[0044] 4. Laser welding machine;

[0045] 5. Material rack;

[0046] 6. Punching frame; 601. Punching cylinder; 602. Punching die head;

[0047] 7. Punching table; 701. Discharge hole;

[0048] 8. Cutting frame; 801. Cutting cylinder; 802. Cutting knife;

[0049] 9. Cut off the guide table;

[0050] 10. Roller; 1001. Bushing block; 1002. Forming motor; 1003. Hanging rod; 1004. Fixing plate; 1005. First spring; 1006. Alignment ring groove;

[0051] 11. Forming pressure column; 1101. Counterweight cross bar; 1102. Correction guide rod; 1103. Adjustment screw; 1104. Spot welding frame; 1141. Table trough; 1142. Limit column; 1105. Ruler; 1106. Welding contact seat; 1161. Insert rod; 1162. Second spring; 1163. Laser welding head. DETAILED DESCRIPTION

[0052] To make the purpose, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the described embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0053] Please refer to Figures 1 to 9 :

[0054] Example 1:

[0055] The present invention proposes an iron core roll forming device and forming process, comprising: a base 1; an operating vertical plate 2 is vertically provided at the upper end of the base 1; a controller 3 and a laser welding machine 4 are fixedly mounted on the operating vertical plate 2; a material rack 5 for storing ungrooved iron sheets is rotatably provided at one end of the operating vertical plate 2, and a winding roller 10 for winding the grooved iron sheets is provided at the other end of the operating vertical plate 2; a stamping mechanism and a cutting mechanism are provided on the operating vertical plate 2 between the material rack 5 and the winding roller 10, the stamping mechanism is close to the material rack 5, and the cutting mechanism is close to the winding roller 10; the stamping mechanism is composed of a stamping frame 6 and a stamping table 7, and the stamping frame 6 is located above the stamping table 7; the cutting mechanism is composed of a cutting frame 8 and a cutting guide table 9, and the cutting frame 8 is located above the cutting guide table 9 above; a forming pressure column 11 is fixed vertically and horizontally on the operating vertical plate 2 just above the winding roller 10, and a movable hole 201 is vertically provided on the operating vertical plate 2 at the position of the winding roller 10, and the winding roller 10 can move vertically in the movable hole 201; a correction mechanism is vertically provided on the forming pressure column 11, and a spot welding mechanism is provided on the correction mechanism and inserted into the forming pressure column 11; the correction mechanism is composed of a gantry structure composed of a counterweight cross bar 1101 and a correction guide rod 1102, which is used to ensure that the core roll is neat during the forming process; the spot welding mechanism is composed of an adjusting screw 1103, a spot welding frame 1104, a ruler 1105 and a welding contact seat 1106, which spot welds the fracture after a roll of iron core is wound and formed.

[0056] Among them, two layers of pressure rods 202 are vertically provided on the operating vertical plate 2 between the material rack 5 and the punching table 7. The unslotted iron sheet passes between the upper and lower pressure rods 202. The upper pressure rod 202 is offset against the material rack 5 to press the material line of the unslotted iron sheet.

[0057] The upper end of the punching frame 6 is a vertical punching cylinder 601 , the piston rod of the punching cylinder 601 is fixedly connected downward to a punching die 602 , and the punching die 602 moves downward to slot the iron sheet passing below.

[0058] A discharge hole 701 corresponding to the stamping die 602 is vertically opened in the stamping platform 7 , and the stamping platform 7 at the lower end of the discharge hole 701 is an outward and downward beveled structure.

[0059] Among them, the middle part of the upper end of the cutting frame 8 is a vertical cutting cylinder 801, and the end of the piston rod of the cutting cylinder 801 is fixedly connected vertically downward with a cutter 802. The cutter 802 moves down to the cutting guide 9 to cut the iron sheet after the slotting.

[0060] The upper end surface of the punching platform 7, the upper end surface of the cutting guide platform 9 and the lower end of the forming pressure column 11 are always on the same horizontal plane.

[0061] Among them, the winding roller 10 rotates on the rotating shaft at one end close to the operating vertical plate 2, and the sleeve block 1001 slides vertically and is clamped in the movable hole 201. The sleeve block 1001 is fixed with a forming motor 1002 at the end away from the winding roller 10 for driving the winding roller 10 to rotate. The upper end of the sleeve block 1001 is vertically provided with a suspension rod 1003, and the upper end of the suspension rod 1003 slides vertically through the fixed plate 1004, and the fixed plate 1004 is fixedly connected to the operating vertical plate 2. The end of the suspension rod 1003 is provided with a baffle, and the suspension rod 1003 between the baffle and the fixed plate 1004 is fitted with a first spring 1005. The first spring 1005 provides an upward pulling force for the sleeve block 1001. The forming motor 1002 drives the winding roller 10 to rotate at an angle consistent with the slot spacing of the iron sheet. The stamping cylinder 601 punches once, and the forming motor 1002 winds one unit.

[0062] Among them, annular alignment grooves 1006 are respectively opened on the roller surfaces at both ends of the winding roller 10, and correction guide rods 1102 are respectively vertically slidably provided at the positions corresponding to the alignment grooves 1006 at both ends of the forming pressure column 11. The lower end of the correction guide rod 1102 is a ball-shaped structure, and the lower end of the correction guide rod 1102 is always slidably placed in the corresponding alignment groove 1006. The upper ends of the two correction guide rods 1102 are provided with a counterweight cross bar 1101. The upper end of 02 is connected to the counterweight cross bar 1101 through a vertical rotation shaft. The slotted iron sheet is wound on the roller 10 between the two alignment ring grooves 1006. The correction guide rod 1102 is tangent to the edge of the wound iron sheet. As the number of wound iron sheets increases, the roller 10 moves downward, the first spring 1005 is compressed, and the extrusion force between the iron sheet on the roller 10 and the forming pressure column 11 increases. The iron sheet at the bottom of the forming pressure column 11 always maintains the same height to keep the winding stable.

[0063] Example 2: On the basis of Example 1, the middle part of the upper end of the counterweight crossbar 1101 is connected to the adjusting screw 1103 for vertical rotation. The counterweight crossbar 1101 on one side of the adjusting screw 1103 is a vertically upward scale 1105. The middle part of the door frame-shaped spot welding frame 1104 is screwed to the adjusting screw 1103 for rotation. The upper end of the scale 1105 slides vertically through the spot welding frame 1104. The lower end of the scale 1105 is the scale zero point. The two ends of the spot welding frame 1104 vertically pass through the counterweight crossbar 1101 and pass through the molding press below. Column 11, the lower end of the spot welding frame 1104 is provided with a table groove 1141 near the side of the cutting frame 8, and a "T"-shaped welding contact seat 1106 is vertically slidably provided in the table groove 1141. The upper end of the welding contact seat 1106 is vertically provided with two symmetrical insertion rods 1161, and a second spring 1162 is set on the insertion rod 1161. The insertion rod 1161 is vertically slidably inserted into the top of the table groove 1141. A limiting column 1142 is vertically symmetrically provided at a position near the lower end of the table groove 1141. The limiting column 1142 is used to stop the welding contact seat 1106. To prevent the welding contact seat 1106 from moving down and dislocating, a pressure sensor is provided at the bottom of the welding contact seat 1106. A laser welding head 1163 is provided on the side of the welding contact seat 1106 away from the cutting frame 8, which is tilted downward. The laser welding head 1163 is connected to the laser welding machine 4. The screw 1103 is adjusted to rotate and adjust the height of the spot welding frame 1104, that is, the windable thickness of the iron sheet on the roller 10. The roller 10 is forced to move downward during the process of the iron sheet being wound and thickened. The correction structure and the cutting mechanism move downward synchronously under the action of their own gravity until the welding contact seat is 1106 moves down and passes through the bottom of the forming pressure column 11 and contacts the iron sheet. The pressure sensor sends a signal, the stamping cylinder 601 stops working, the cutting cylinder 801 starts working, the forming motor 1002 continues to rotate, and the laser welding head 1163 is preheated and started. When the lower end of the welding contact seat 1106 contacts the cut-off fracture, the welding contact seat 1106 moves down by the thickness of an iron sheet, the signal of the pressure sensor changes suddenly, the forming motor 1002 stops working, and the laser welding head 1163 starts synchronously to weld the iron sheet fracture, and the iron core roll is formed.

[0064] The following further explains and illustrates the functions and effects of the above structures so that those skilled in the art can better understand the present technical solution:

[0065] The base 1 and the vertically arranged operating stand 2 constitute the main support structure of the equipment, ensuring the spatial stability of each functional module. The material rack 5 and the winding roller 10 are placed at both ends to form a continuous processing path. After the ungrooved iron sheet is released from the material rack 5, it is pressed and guided by the upper and lower layers of offset pressure rods 202 to avoid material line deviation. The offset design of the pressure rod 202 adjusts the tension of the iron sheet through friction to ensure the stability of material transmission in the subsequent stamping and winding processes. The upper surfaces of the stamping table 7 and the cutting guide table 9 are kept at the same horizontal plane, and cooperate with the bottom plane of the forming pressure column 11 to form a continuous support surface, so that the iron sheet is always in a flat state during the stamping, grooving, cutting and winding process, reducing the risk of deformation.

[0066] In the stamping mechanism, the stamping cylinder 601 drives the stamping die 602 to periodically slot the iron sheet. The discharge hole 701 of the stamping table 7 adopts a beveled structure design to facilitate the rapid discharge of stamping waste and avoid blockage. The winding roller 10 is vertically floated by an elastic suspension system composed of a sleeve block 1001 and a first spring 1005. When the forming motor 1002 drives the winding roller 10 to rotate, its rotation angle is strictly synchronized with the stamping frequency of the stamping cylinder 601 to ensure that the spacing between each slot is consistent with the winding pitch. The alignment ring grooves 1006 at both ends of the winding roller 10 are slidably matched with the ball head end of the correction guide rod 1102, continuously applying radial constraints to the edge of the iron sheet during the winding process, forcing the edges of the winding layers to be aligned, and avoiding looseness or tilting caused by misalignment between the iron core layers.

[0067] In the correction mechanism, the gantry structure formed by the counterweight crossbar 1101 and the correction guide rod 1102 provides constant downward pressure through its own weight. As the thickness of the core coil increases, the winding roller 10 moves downward to compress the first spring 1005. At this time, the correction guide rod 1102 slides along the alignment ring groove 1006 and maintains contact with the edge of the coil layer, so that the forming pressure column 11 always applies uniform pressure to the outermost iron sheet to ensure the density of the coil layer. The adjustment screw 1103 of the spot welding mechanism cooperates with the ruler 1105. By rotating and adjusting the initial height of the spot welding frame 1104, the target thickness threshold of the core coil is preset. When the coil thickness reaches the set value, the pressure sensor at the bottom of the welding contact seat 1106 contacts the surface of the iron sheet, triggering the controller 3 to shut down the stamping cylinder 601 and start the cutting cylinder 801, realizing the automatic switching between thickness monitoring and processing termination.

[0068] During the cutting process, the forming motor 1002 keeps running, causing the cut end of the iron sheet to move forward as the winding roller 10 rotates to below the welding contact seat 1106. The welding contact seat 1106 forms a floating contact structure through the second spring 1162 and the limit column 1142. When the cut end moves below it, the iron sheet's winding thickness suddenly decreases, causing the welding contact seat 1106 to move down by a plate thickness. The sudden change in the pressure sensor signal triggers the controller 3 to stop winding and activate the laser welding head 1163. After preheating, the tilted laser welding head 1163 performs instantaneous spot welding on the cut end, using the winding tension of the iron sheet to ensure a tight fit and ensure welding strength. The entire process achieves full automation of the "winding-monitoring-cutting-welding" process through the precise coordination of mechanical linkage and electrical control signals, significantly improving the efficiency and consistency of iron core roll forming.

[0069] Working principle:

[0070] The ungrooved iron sheet coil is mounted on the material rack 5, and the free end of the iron sheet is pulled through the gap between the pressure rod 202, the surface of the punching table 7, and the surface of the cutting guide table 9 in sequence, and is fixedly wound between the alignment ring grooves 1006 of the winding roller 10;

[0071] The height of the spot welding frame 1104 is adjusted by rotating the adjustment screw 1103 so that the scale 1105 indicates the preset core coil thickness threshold, and the welding parameters of the laser welding machine 4 are set;

[0072] Start the punching cylinder 601 and the forming motor 1002. The punching die 602 periodically slots the passing iron sheet. The forming motor 1002 synchronously drives the winding roller 10 to rotate the coil at an angular velocity that matches the slotting interval.

[0073] During the winding process of the slotted iron sheet, the ball end of the correction guide rod 1102 slides along the alignment ring groove 1006, forcing the edges of the coil layer to align. As the coil thickness increases, the winding roller 10 presses down and compresses the first spring 1005, and the forming pressure column 11 continues to apply downward pressure to keep the coil layer dense.

[0074] When the coil thickness reaches the threshold, the welding contact seat 1106 contacts the surface of the iron sheet, triggering the pressure sensor. The controller 3 immediately stops the punching cylinder 601 and starts the cutting cylinder 801 to cut the iron sheet. At the same time, the forming motor 1002 keeps running to pull the cut edge forward.

[0075] When the fracture moves to below the welding contact seat 1106, the downward movement of the iron sheet triggers a sudden change in the pressure signal. The controller 3 synchronously stops the forming motor 1002 and activates the laser welding head 1163 to perform spot welding on the fracture to complete the core roll forming.

[0076] In this article, there are several points to note:

[0077] 1. The drawings of the embodiments of the present invention only relate to the structures related to the embodiments of the present invention. Other structures may refer to conventional designs.

[0078] 2. In the absence of conflict, the embodiments of the present invention and the features therein may be combined with each other to form new embodiments.

[0079] The above are only specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with this technical field can easily think of changes or replacements within the technical scope disclosed by the present invention, which should be covered by the scope of protection of the present invention.

Claims

1. An iron core roll forming device, comprising: A base (1); an operating vertical plate (2) is vertically provided at the upper end of the base (1); a controller (3) and a laser welding machine (4) are fixedly mounted on the operating vertical plate (2); a material rack (5) for storing ungrooved iron sheets is rotatably provided at one end of the operating vertical plate (2), and a roller (10) for winding the grooved iron sheets is provided at the other end of the operating vertical plate (2); it is characterized in that a punching mechanism and a cutting mechanism are provided on the operating vertical plate (2) between the material rack (5) and the roller (10), the punching mechanism is close to the material rack (5), and the cutting mechanism is close to the roller (10); the punching mechanism is composed of a punching frame (6) and a punching table (7), and the punching frame (6) is located above the punching table (7); the cutting mechanism is composed of a cutting frame (8) and a cutting guide table (9), and the cutting frame (8) is located between the cutting guide table (9) and the cutting guide table (9). ); a forming pressure column (11) is fixed vertically and horizontally on the operating vertical plate (2) directly above the winding roller (10); a movable hole (201) is vertically provided on the operating vertical plate (2) at the position of the winding roller (10), and the winding roller (10) can move vertically in the movable hole (201); a correction mechanism is vertically provided on the forming pressure column (11), and a spot welding mechanism is provided on the correction mechanism and inserted into the forming pressure column (11); the correction mechanism is composed of a gantry structure composed of a counterweight cross bar (1101) and a correction guide rod (1102), which is used to ensure that the iron core roll is neat during the forming process; the spot welding mechanism is composed of an adjusting screw (1103), a spot welding frame (1104), a ruler (1105) and a welding contact seat (1106), and the fracture is spot welded and fixed after a roll of iron core is wound and formed;The middle part of the upper end of the counterweight crossbar (1101) is connected to the adjusting screw (1103) in a vertical rotation manner. The counterweight crossbar (1101) on one side of the adjusting screw (1103) is a vertically upward scale (1105). The middle part of the door frame-shaped spot welding frame (1104) is screwed to the adjusting screw (1103) in a rotational manner. The upper end of the scale (1105) slides vertically through the spot welding frame (1104). The lower end of the scale (1105) is the scale zero point. The two ends of the spot welding frame (1104) vertically pass through the counterweight crossbar (1101) and pass through the forming pressure column (11) below. The spot welding frame (1104) A platform groove (1141) is provided on one side of the lower end of the cutting frame (8) near the cutting frame (8), and a "T"-shaped welding contact seat (1106) is vertically slidably provided in the platform groove (1141). Two symmetrical insertion rods (1161) are vertically provided on the upper end of the welding contact seat (1106). A second spring (1162) is mounted on the insertion rod (1161). The insertion rod (1161) is vertically slidably inserted into the top of the platform groove (1141). A limiting column (1142) is vertically symmetrically provided at a position near the lower end of the platform groove (1141). The limiting column (1142) is used to stop the welding contact seat (1106). , to prevent the welding contact seat (1106) from moving down and dislocating, a pressure sensor is provided at the bottom of the welding contact seat (1106), and a laser welding head (1163) is provided on the side of the welding contact seat (1106) away from the cutting frame (8) and tilted downward, and the laser welding head (1163) is connected to the laser welding machine (4), and the screw (1103) is adjusted to rotate and adjust the height of the spot welding frame (1104), that is, the windable thickness of the iron sheet on the roller (10), and the roller (10) is forced to move downward during the process of the iron sheet being wound and thickened, and the correction structure and the cutting mechanism follow and move downward synchronously under the action of their own gravity until the welding is completed. The contact seat (1106) moves downward and passes through the bottom of the forming pressure column (11) to contact the iron sheet. The pressure sensor sends a signal, the punching cylinder (601) stops working, the cutting cylinder (801) starts working, the forming motor (1002) continues to rotate, the laser welding head (1163) is preheated and started, and when the lower end of the contact seat (1106) to be welded contacts the cut-off fracture, the welding contact seat (1106) moves downward by a distance equal to the thickness of the iron sheet. The signal of the pressure sensor changes suddenly, the forming motor (1002) stops working, and the laser welding head (1163) starts to weld the iron sheet fracture synchronously, and the iron core is rolled into shape.

2. The core roll forming equipment according to claim 1, characterized in that: An upper and lower pressure rod (202) are vertically provided on the operating vertical plate (2) between the material rack (5) and the punching table (7); the unslotted iron sheet passes between the upper and lower pressure rods (202); the upper pressure rod (202) is offset and leans against the material rack (5) to press the material line of the unslotted iron sheet.

3. The core roll forming equipment according to claim 1, characterized in that: The upper end of the punching frame (6) is a vertical punching cylinder (601), and the piston rod of the punching cylinder (601) is fixedly connected downward to a punching die (602), and the punching die (602) moves downward to slot the iron sheet passing below.

4. The core roll forming equipment according to claim 3, characterized in that: A discharge hole (701) corresponding to the stamping die head (602) is vertically opened in the stamping platform (7), and the stamping platform (7) at the lower end of the discharge hole (701) is an outward and downward beveled structure.

5. The core roll forming equipment according to claim 1, characterized in that: The middle part of the upper end of the cutting frame (8) is a vertical cutting cylinder (801), and the end of the piston rod of the cutting cylinder (801) is fixedly connected vertically downward with a cutter (802). The cutter (802) moves down to the cutting guide table (9) to cut the iron sheet after the slot is passed.

6. The core roll forming equipment according to claim 1, characterized in that: The upper end surface of the punching platform (7), the upper end surface of the cutting guide platform (9) and the lower end of the forming pressure column (11) are always on the same horizontal plane.

7. The core roll forming equipment according to claim 3, characterized in that: The roller (10) is rotated on a shaft at one end thereof close to the operating vertical plate (2), and the sleeve block (1001) is vertically slidably engaged in the movable hole (201). The sleeve block (1001) is fixedly provided with a forming motor (1002) at one end thereof away from the roller (10) for driving the roller (10) to rotate. A suspension rod (1003) is vertically provided at the upper end of the sleeve block (1001), and the upper end of the suspension rod (1003) vertically slides through the fixed plate (1004). The fixed plate (100 4) is fixedly connected to the operating vertical plate (2), a baffle is provided at the end of the suspension rod (1003), a first spring (1005) is mounted on the suspension rod (1003) between the baffle and the fixed plate (1004), and the first spring (1005) provides an upward pulling force for the sleeve block (1001). The forming motor (1002) drives the winding roller (10) to rotate at an angle consistent with the slot spacing of the iron sheet. The stamping cylinder (601) stamps once, and the forming motor (1002) winds one unit.

8. The core roll forming equipment according to claim 1, characterized in that: The roller surfaces at both ends of the roller (10) are respectively provided with annular alignment grooves (1006), and the two ends of the forming pressure column (11) are respectively provided with vertically sliding correction guide rods (1102) at positions corresponding to the alignment grooves (1006), the lower end of the correction guide rod (1102) is a ball-shaped structure, and the lower end of the correction guide rod (1102) is always slidably placed in the corresponding alignment groove (1006), and a counterweight cross bar (1101) is provided between the upper ends of the two correction guide rods (1102). 02) is connected to the counterweight cross bar (1101) through a rotating shaft for vertical rotation. The slotted iron sheet is wound on the roller (10) between the two alignment ring grooves (1006). The correction guide rod (1102) is tangent to the edge of the wound iron sheet. As the number of wound iron sheets increases, the roller (10) moves downward, the first spring (1005) is compressed, and the extrusion force between the iron sheet on the roller (10) and the forming pressure column (11) increases. The iron sheet at the bottom of the forming pressure column (11) always maintains the same height to keep the winding stable.

9. A forming process for an iron core roll forming device, applicable to the iron core roll forming device according to any one of claims 1 to 8, characterized in that: The following steps are involved: S1. Loading and positioning: The unslotted iron sheet coil is mounted on the material rack (5), and the free end of the iron sheet is pulled sequentially through the gap between the pressure rod (202), the surface of the punching table (7), and the surface of the cutting guide table (9), and is fixedly wound between the alignment ring grooves (1006) of the winding roller (10); S2. Parameter setting: adjusting the height of the spot welding frame (1104) by rotating the adjustment screw (1103) so that the scale (1105) indicates the preset core roll thickness threshold, and setting the welding parameters of the laser welding machine (4); S3.Continuous molding: a. Start the stamping cylinder (601) and the forming motor (1002), the stamping die (602) periodically slots the iron sheet passing through, and the forming motor (1002) synchronously drives the roll (10) to rotate the coil at an angular velocity that matches the slot spacing; b. During the winding process of the slotted iron sheet, the ball end of the correction guide rod (1102) slides along the alignment ring groove (1006), forcing the edges of the coils to align; As the roll thickness increases, the roll roller (10) presses down to compress the first spring (1005), and the forming pressure column (11) continuously applies downward pressure to keep the roll layer dense; S4. Thickness monitoring and cutting: When the coil thickness reaches the threshold, the welding contact seat (1106) contacts the surface of the iron sheet to trigger the pressure sensor, and the controller (3) immediately stops the punching cylinder (601) and starts the cutting cylinder (801) to cut the iron sheet. At the same time, the forming motor (1002) keeps running to pull the fracture forward; S5. Fracture welding: When the fracture moves to the bottom of the welding contact seat (1106), the downward movement of the iron sheet triggers a sudden change in the pressure signal, and the controller (3) synchronously stops the forming motor (1002) and activates the laser welding head (1163), spot welding the fracture to complete the core roll forming.

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