Laser peeling method and system for coil in network filter shell

Abstract

The invention belongs to the technical field of network transformers, and discloses a laser peeling method and system for a coil in a network filter shell, which are used for burning and peeling the surfaces of all winding wires of the network filter coil before pin winding. Straightening all winding wires on the coil in the branching state towards the outside of the coil and keeping the winding wires in a parallel state; and then determining a burning area of the winding wire, adjusting laser equipment to align with the burning area to carry out mobile laser irradiation, and burning and peeling all winding wires on the single side of at least one coil. The system comprises a laser which is fixed on an operation table top through a fixing frame; the jig is used for placing a plurality of coils or rubber shells with the coils; the jig fixing table is arranged on the operation table top and used for fixing a jig and burning the emitting end face, facing the laser, of the jig. The method is simple and efficient.

Description

Technical Field

[0001] The invention belongs to the technical field of line splitting equipment, and in particular relates to a method and system for laser peeling of coils inside a network filter shell. Background Art

[0002] A network transformer, also known as a network isolation transformer or pulse transformer, is an electronic component used for data transmission and signal isolation. It is widely used in network communications, industrial control, power systems, and other fields. A network transformer consists of a core material, coil structure, insulation material, pins and welding, shielding, and packaging. The core typically uses a ferrite core, and the coil can be wound in a single or multi-layer manner. The insulation material is used to ensure electrical isolation between the coils. The pins are made of copper or other conductive materials and are connected to the coil by welding. To reduce electromagnetic interference, some network transformers are designed with metal shielding. The outer casing can be plastic or metal to protect the internal structure and provide mechanical support.

[0003] The manufacturing process for network transformers includes core preparation, coil winding, pin soldering, insulation, shielding, packaging, testing, and burn-in. According to design requirements, the primary and secondary coils are wound around the core. This process is typically done manually, although a small amount of automated equipment is used specifically for network transformer winding. The wound coils are then soldered to the pins to ensure connection reliability and electrical performance.

[0004] Before winding, the winding wires of the winding (the magnetic ring structure after the core is wound) need to be combed. This means that the corresponding number of winding wires are straightened to form two strands. After manual separation, the wires are placed inside the plastic shell of the network transformer for the foot winding process. After placement in the shell, the winding wires need to be wound around the pin structure on the inside of the plastic shell. However, the winding wires commonly used are wrapped with external materials such as lacquer or rubber. This insulating surface is not conductive when wound around the metal pins, so it is necessary to partially peel the wire before winding. However, the peeling area must be accurate. Otherwise, excessive peeling can cause the exposed parts of the winding wires between different coils in the plastic shell to short-circuit, causing the network filter to fail. Summary of the Invention

[0005] In order to solve the problems existing in the prior art, the present invention provides a method and system for laser peeling of the coil inside the shell of a network filter, which aims to accurately process the insulation layer on the surface of the winding wire by laser before winding the foot, thereby meeting the winding requirements while avoiding short circuits between the winding wires of the coil inside the plastic shell.

[0006] The technical solution adopted in the present invention is: In a first aspect, the present invention provides a method for laser peeling of a coil inside a network filter housing, which is used to burn and peel the surface of all winding wires of the network filter coil before winding. The specific steps are as follows: First, straighten all the winding wires on the coil in the split state outward and keep them parallel; Then, the burning area of the winding wire is determined, and the laser device is adjusted to align with the burning area for mobile laser irradiation, so as to burn and peel all the winding wires on one side of at least one coil.

[0007] In combination with the first aspect, the present invention provides a first embodiment of the first aspect. When determining the burning area of the winding wire, when the coil is outside the plastic shell of the network filter and the winding wire is straightened outward, the length of the winding wire is calculated from the root of the coil, and the estimated length of the winding wire sunk into the plastic shell is added to the calculated length. Then, a length range of 2-10 mm is determined as the burning area.

[0008] In combination with the first aspect, the present invention provides a second embodiment of the first aspect. When determining the burning area of the winding wire, when the coil is pressed into the plastic shell of the network filter and the winding wire is straightened outward, a length range of 2-10 mm is determined between the pins of the plastic shell and the external pins as the burning area.

[0009] In combination with the first aspect, the present invention provides a third embodiment of the first aspect, wherein when the laser device is aimed at the burning area for moving laser irradiation, the laser device is first rotated around the circumferential direction of the winding wire for burning during irradiation, and then after rotating and burning at least 60 degrees, the laser device is moved to the next winding wire for circumferential rotation burning.

[0010] In combination with the third embodiment of the first aspect, the present invention provides a fourth embodiment of the first aspect, wherein the laser beam of the laser device covers the length of the winding wire within the length range of the burning area, and the burning of a single winding wire is completed by the laser device rotating circumferentially around the winding wire by at least 60 degrees.

[0011] In combination with the third embodiment of the first aspect, the present invention provides a fifth embodiment of the first aspect, wherein the laser beam of the laser device covers a length range of the winding wire that is less than the length of the burning area. The laser device is first moved along the length direction of the winding wire to burn to form a peeling area whose length belongs to the length range of the burning area. Then, the laser device is rotated circumferentially around the winding wire, and moved linearly in the opposite direction of the last displacement for the same length and then rotated. The linear displacement and rotational displacement processes are repeated until the burning area reaches the set length range and angle range.

[0012] In a second aspect, the present invention further provides a laser peeling system, which is applied to any of the above-mentioned methods for laser peeling of coils inside a network filter shell, comprising: The laser is fixed on the operating table through a fixing bracket; A fixture for placing several coils or plastic shells containing coils; and The fixture fixing table is set on the operating table to fix the fixture and direct the fixture toward the emitting end face of the laser for burning.

[0013] In combination with the second part, the present invention also provides a first embodiment of the second aspect, which further includes a laser translation frame arranged on the operating table, and the fixed frame is arranged on the laser translation frame and moves back and forth linearly along the laser translation frame.

[0014] In combination with the first embodiment of the second part, the present invention also provides a second embodiment of the second aspect, wherein a lifting frame is further provided between the fixed frame and the laser translation frame, and the fixed frame performs reciprocating motion in a vertical direction relative to the jig through the lifting frame.

[0015] In combination with the second part, the present invention also provides a third embodiment of the second aspect, further comprising a jig moving frame provided on the operating platform, wherein the jig fixing table reciprocates on the jig moving frame along the length direction of the jig moving frame; The jig fixing table is rotatably connected to a jig frame, and the jig frame is controlled by a rotary motor arranged on the jig fixing table to rotate relative to the beam direction of the laser.

[0016] The beneficial effects of the present invention are: (1) The present invention adopts two methods, namely, laser peeling of the coil that has been encased in the plastic shell, and laser peeling of the winding wire of the coil that has not been encased in the plastic shell, so that stable peeling can be achieved in either step, which provides convenience for the subsequent foot winding process; (2) When the present invention is used to peel a coil that is not enclosed in a plastic shell, a length value is first calculated as a basic length, that is, it is expected that the winding wire will be at the actual position of the pin part after being partially pressed into the plastic shell after being enclosed in the plastic shell, so that the peeling is more accurate in the early stage and the insulation layer of the winding wire at the pin can be ensured to be removed after the subsequent enclosed shell; (3) The present invention rotates the winding wire and the laser device so that the laser beam, which originally could only burn the winding wire from one side, can cover more areas of the winding wire, thereby improving the peeling effectiveness. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a first isometric view of a peeling system according to an embodiment of the present invention; Figure 2 is a left side view of the peeling system in an embodiment of the present invention; Figure 3 is a right side view of the peeling system in an embodiment of the present invention; Figure 4 is a second axonometric view of the peeling system according to an embodiment of the present invention; Figure 5 is a flow chart of a first laser skin peeling method according to an embodiment of the present invention; Figure 6 This is a flow chart of a second laser skin peeling method in an embodiment of the present invention.

[0018] In the figure: 1-laser, 2-fixed frame, 3-lifting frame, 4-laser translation frame, 5-fixed fixture table, 6-fixture moving frame, 7-rotating motor. DETAILED DESCRIPTION

[0019] The present invention will be further explained below with reference to the accompanying drawings and specific embodiments.

[0020] To make the objectives, technical solutions, and advantages of the embodiments of the present application more clear, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Generally, the components of the embodiments of the present application described and shown in the drawings herein can be arranged and designed in various different configurations.

[0021] Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the present application for protection, but merely represents selected embodiments of the present application. All other embodiments obtained by persons of ordinary skill in the art based on the embodiments in the present application without making any creative efforts shall fall within the scope of protection of the present application.

[0022] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0023] In the description of this application, it should be noted that if the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. appear, the orientation or position relationship indicated is based on the orientation or position relationship shown in the accompanying drawings, or the orientation or position relationship in which the product of the application is usually placed when in use. It is only for the convenience of describing this application and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, it cannot be understood as a limitation on this application. In addition, if the terms "first", "second", etc. appear in the description of this application, they are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

[0024] Furthermore, the use of terms such as "horizontal" and "vertical" in the description of this application does not necessarily imply that a component must be absolutely horizontal or suspended, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical" and does not mean that the structure must be completely horizontal, but rather that it can be slightly tilted.

[0025] It should also be noted that, unless otherwise expressly specified or limited, the terms "disposed," "installed," "connected," and "connected" should be understood broadly. For example, they may refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. A person of ordinary skill in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0026] Example 1: This embodiment discloses a laser peeling method for network filter coils, which burns and peels a portion of the winding wire before winding, thereby removing the insulation layer on its surface, facilitating direct winding and improving efficiency.

[0027] It should be noted that the materials involved in this embodiment are components of a network filter, mainly a number of coils arranged inside the network filter. The entire network filter manufacturing process is as follows: Coil winding → coil casing → foot winding → testing → packaging The network filter involved in this embodiment is only one of several electronic components that use inductor coils as basic devices, and also includes network transformers, etc. This embodiment only refers to the network filter, but is not limited to this. After the coils are wound and formed, they are processed manually or automatically to form two sets of wire harnesses on both sides of each coil. Each set of wire harnesses has the same number of winding wires, which include two types of winding wires, namely, lacquered wire and rubber wire. Insulation layers are provided to prevent the coils in the network filter's plastic shell from short-circuiting. However, since the winding wires themselves need to be connected to the external circuit, the insulation layer needs to be removed when winding them to ensure that each connected pin and the corresponding external pin can conduct current to form a path.

[0028] The existing method is to remove the external insulating layer material by laser or other means after the foot is wound, but this method is unstable because the winding wire will be entangled and stacked after winding, and external processing cannot affect the internal shielded part, resulting in some insulating layer still existing on its surface, affecting its conductive performance.

[0029] The method in this embodiment is to perform skin removal by laser before wrapping the foot, and then wrap the foot. It is only necessary to determine the position in advance and then burn and peel the skin with laser, which has little effect on the conductive performance after wrapping the foot.

[0030] Specifically, the coil in the split state obtained in the previous processing flow is first fixed, and all the winding wires of the coil are kept straightened outward in the split state. At this time, most of each winding wire is parallel after starting from the coil.

[0031] Then determine the burning area of each winding wire, determine a distance value compared to the outer end of the winding wire or the distance value from the straight line passing through the center of the coil and perpendicular to all the winding wires, adjust the relative position relationship between the laser device and the winding wire according to the distance value, aim at the burning area for mobile laser irradiation and peeling, and after peeling, perform peeling inspection by visual or test equipment. If it meets the standard, the peeling process is completed. If it does not meet the standard, it will be burned again or recycled as waste based on the integrity of the winding wire.

[0032] Furthermore, when determining the burning area, a judgment is made based on the state of the coil.

[0033] Reference Figure 5 If the coil is outside the plastic shell of the network filter, the length of the winding wire is calculated from the root of the coil when the winding wire is straightened outward, plus the estimated length of the coil sunk into the plastic shell, and then a length range of 2-10mm is determined as the burning area.

[0034] Reference Figure 6 When the coil is pressed into the plastic shell of the network filter and the winding wire is straightened outward, a 2-10 mm length range is determined between the pin of the plastic shell and the external pin as the burning area. In this embodiment, a 5 mm length range is used as the determined burning area for burning. The area where the laser beam falls on the winding wire covers a length of 5 mm. A single irradiation of a fixed time can complete the formation of a 5 mm length of the burning area.

[0035] Furthermore, when the laser device is aimed at the burning area for moving laser irradiation, the laser device is first rotated around the circumferential direction of the winding wire for burning during irradiation, and then rotated and burned at least 60 degrees, and then the laser device is moved to the next winding wire for circumferential rotation burning.

[0036] The laser beam of the laser device covers the length of the winding wire within the length range of the burn zone, and the laser device is rotated at least 60 degrees around the winding wire to complete the burning of a single winding wire. The laser beam of the laser device covers the length range of the winding wire less than the length range of the burn zone. The laser device is first moved along the length of the winding wire to burn a peeling area within the length range of the burn zone. The laser device is then rotated around the winding wire circumference, moving linearly in the opposite direction of the previous displacement by the same length, and then rotating. The linear and rotational displacement processes are repeated until the burn zone reaches the set length and angle ranges.

[0037] Furthermore, the laser beam of the laser device covers the length of the winding wire within the length range of the burning area, and the laser device is rotated at least 60 degrees around the winding wire to complete the burning of a single winding wire.

[0038] Based on the above-mentioned 5mm laser coverage area length method, the width of the irradiated area is described as a percentage of the cross-sectional side length of the winding wire. The width value of a single laser beam fixedly irradiated on the winding wire is close to 50%, and then the angle of rotation and burning is 60 degrees. Single-sided rotation can increase the coverage in the width direction to about 80%. If the fixed angle irradiation is used as a fixed value, the laser is swung 160 degrees left and right to move the irradiation, which can meet the requirement that the burning area of the winding wire with a length of 5mm can completely cover the curved surface of the winding wire, thereby achieving a better peeling effect.

[0039] It should also be noted that the laser 1 includes two schemes: a single laser beam and multiple parallel laser beams. The intervals between the multiple parallel laser beams correspond to adjacent winding wires or winding wires with equal intervals. It can simultaneously move and irradiate multiple winding wires at a time to improve the peeling efficiency.

[0040] Furthermore, the laser ablation peeling method in this embodiment is based on an automated laser peeling system, referring to Figures 1-4 The figure shows the structural features of the laser peeling system, including: The laser 1, placed at the top, is secured to the operating table by a fixture 2. A jig is used to hold several coils or coil-containing plastic shells. A jig fixture 5, located on one side of the jig fixture, is installed on the operating table to secure the jig and direct it toward the emitting end face of the laser 1 for burning.

[0041] Furthermore, the system includes a laser translation frame 4 mounted on the operating table. The fixed frame 2 has a base at its base, which is bolted to the slide of the laser translation frame 4 and moves back and forth along the laser translation frame 4 via the slide. A lifting frame 3 is also installed between the fixed frame 2 and the laser translation frame 4. The lifting frame 3 allows the fixed frame 2 to reciprocate vertically relative to the fixture. In this embodiment, the fixed frame 2 can be automatically controlled by a PLC program to perform three-axis spatial displacement on the table.

[0042] Furthermore, the system also includes a jig moving frame 6 arranged on the operating platform, and the jig fixing table 5 reciprocates on the jig moving frame 6 along the length direction of the jig moving frame 6; the jig frame is rotatably connected to the jig fixing table 5, and the jig frame is controlled by a rotating motor 7 arranged on the jig fixing table 5 to rotate relative to the beam direction of the laser 1.

[0043] The present invention is not limited to the above optional embodiments. Anyone can derive various other forms of products based on the teachings of the present invention. The above specific embodiments should not be construed as limiting the scope of protection of the present invention. The scope of protection of the present invention shall be based on the scope defined in the claims, and the description can be used to interpret the claims.

Claims

1. A laser peeling method for coils inside a network filter housing, which is used to burn and peel all the winding wire surfaces of the network filter coil before winding, and is characterized by: The specific steps are as follows: First, straighten all the winding wires on the coil in the split state outward and keep them parallel; Then, the burning area of the winding wire is determined, and the laser device is adjusted to align with the burning area for mobile laser irradiation, so as to burn and peel all the winding wires on one side of at least one coil.

2. The method for laser peeling of the coil inside the housing of a network filter according to claim 1, characterized in that: When determining the burning area of the winding wire, when the coil is outside the plastic shell of the network filter, with the winding wire straightened outward, the length is calculated from the root of the winding wire at the coil, plus the estimated length when it is installed and sunk into the plastic shell, and then a length range of 2-10mm is determined as the burning area.

3. The method for laser peeling of coils inside a network filter housing according to claim 1, characterized in that: When determining the burning area of the winding wire, when the coil is pressed into the plastic shell of the network filter and the winding wire is straightened outward, a length range of 2-10mm is determined between the pins of the plastic shell and the external pins as the burning area.

4. The method for laser peeling of coils inside a network filter housing according to claim 1, characterized in that: When the laser device is aimed at the burning area for moving laser irradiation, the laser device is first rotated around the circumferential direction of the winding wire for burning during irradiation, and then rotated and burned at least 60 degrees, and then the laser device is moved to the next winding wire for circumferential rotation burning.

5. The method for laser peeling of coils inside a network filter housing according to claim 4, characterized in that: The laser beam of the laser device covers the length of the winding wire within the length range of the burning area, and the laser device is rotated at least 60 degrees around the winding wire to complete the burning of a single winding wire.

6. The method for laser peeling of coils inside a network filter housing according to claim 4, characterized in that: The laser beam of the laser device covers a range where the length of the winding wire is less than the length of the burning area. The laser device is first moved along the length direction of the winding wire to burn and form a peeling area whose length belongs to the length range of the burning area. Then, the laser device is rotated circumferentially around the winding wire, and is moved linearly in the opposite direction of the previous displacement by the same length and then rotated. The linear displacement and rotational displacement processes are repeated until the burning area reaches the set length range and angle range.

7. A laser peeling system, characterized by: The method for laser peeling of a coil inside a network filter shell as described in any one of claims 1 to 6 comprises: The laser (1) is fixed on the operating table via a fixing frame (2); A fixture for placing several coils or plastic shells containing coils; and A fixture fixing table (5) is arranged on the operating table and is used to fix the fixture and burn the fixture toward the emission end face of the laser (1).

8. The laser skin peeling system according to claim 7, characterized in that: It also includes a laser translation frame (4) arranged on the operating table, and the fixed frame (2) is arranged on the laser translation frame (4) and reciprocates linearly along the laser translation frame (4).

9. The laser skin peeling system according to claim 8, characterized in that: A lifting frame (3) is further provided between the fixed frame (2) and the laser translation frame (4), and the fixed frame (2) performs reciprocating motion in a vertical direction relative to the fixture via the lifting frame (3).

10. The laser skin peeling system according to claim 7, characterized in that: It also includes a jig moving frame (6) arranged on the operating platform, and the jig fixing platform (5) reciprocates on the jig moving frame (6) along the length direction of the jig moving frame (6); A jig frame is rotatably connected to the jig fixing platform (5), and the jig frame is controlled to rotate relative to the direction of the beam of the laser (1) by a rotating motor (7) arranged on the jig fixing platform (5).

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