A forming process for an inductor coil

Abstract

The application relates to the field of electronic component manufacturing, in particular to a forming process of an inductor coil, which comprises the following steps: step one: using a first bending jig to preliminarily bend the end part of a double-layer coil; step two: using a second bending jig to further bend the preliminarily bent end part of the coil to reach a preset bending shape; and step three: using a detection and correction jig to correct the bent end part of the coil to ensure that the shape meets the forming requirements. The application solves the problems that in the prior art, the bending shape and size of the end part of the inductor coil are difficult to accurately control, the electromagnetic performance and connection stability are affected, and the lack of effective detection means leads to high product failure rate and increased production cost.

Description

Technical Field

[0001] This application relates to the field of electronic component manufacturing, and in particular to a forming process for an inductor coil. Background Technology

[0002] With the rapid development of electronic technology, inductors, as key components in electronic circuits, are widely used in power conversion, filtering, energy storage, and other fields. As electronic devices move towards miniaturization and high performance, higher demands are placed on the precision, stability, and production efficiency of inductors. Especially in power supply systems, the performance of the electromagnetic induction coil module directly affects the efficiency and stability of the entire power system.

[0003] The related technology discloses an electromagnetic induction coil module for a power supply device, which adopts a dual-coil structure, including an outer coil and an inner coil. The two are formed by bending the same wire to form a concentric circle structure and are fixedly connected by multiple sets of fixing devices to prevent coil deformation.

[0004] Current technologies primarily focus on the overall fixing method of the coil module, while lacking in-depth research and effective solutions for the precise bending and correction process at the coil ends. This results in difficulty in precisely controlling the bending shape and size of the coil ends during actual production, thus affecting the electromagnetic performance of the coil and the stability of its connection with other components. Furthermore, the lack of effective inspection methods makes it difficult to ensure that the forming quality of each coil meets requirements, thereby increasing product defect rates and production costs. Summary of the Invention

[0005] To address the problems in the prior art where the bending shape and size of the inductor coil ends are difficult to control precisely, affecting electromagnetic performance and connection stability, and where the lack of effective testing methods leads to high product defect rates and increased production costs, this application provides a forming process for an inductor coil.

[0006] The forming process of an inductor coil provided in this application adopts the following technical solution:

[0007] A forming process for an inductor coil includes the following steps:

[0008] Step 1: Use the first bending fixture to perform a preliminary bend on the ends of the double-layer coil;

[0009] Step 2: Use the second bending fixture to further bend the initially bent coil end to achieve the preset bending shape;

[0010] Step 3: Use a testing and calibration fixture to calibrate the ends of the bent coil to ensure that its shape meets the forming requirements.

[0011] By adopting the above technical solution, the dual-coil structure of the electromagnetic induction coil module of the power supply device in the related technology has shortcomings in the precise bending and correction process of the coil ends during production. This makes it difficult to accurately control the bending shape and size, affecting the electromagnetic performance and connection stability. In addition, the lack of effective detection methods increases the defect rate and production cost. The inductor coil forming process provided in this application first uses a first bending fixture to pre-bend the ends of the double-layer coil, then uses a second bending fixture to further bend it to the preset shape, and finally uses a detection and correction fixture to correct the bent coil ends to ensure that its shape meets the forming requirements. This solves the problem of inaccurate bending of the coil ends in the related technology, ensures the electromagnetic performance of the coil and the connection stability with other components, and reduces the product defect rate and saves production costs through effective correction methods.

[0012] Optional, the specific steps in step one are as follows:

[0013] A1: The first connecting block, the first positioning post, the first positioning ring and the first outer bending seat are all fixed on the base plate. An annular positioning cavity for positioning the inner coil is formed between the first positioning post and the first positioning ring. The first positioning ring is also provided with a receiving cavity for accommodating the connecting wire.

[0014] A2: Place the double-layer inductor coil on the first positioning seat, align the inner coil with the annular positioning cavity, so that the inner coil is sleeved on the first positioning post, and the connecting wire is located in the accommodating cavity. At the same time, the coil is sleeved on the first positioning ring.

[0015] A3: Fix the first inner bending seat onto the first positioning post;

[0016] A4: The inner coil is bent using the inner bend radius and the first inner bend channel to form the first inner bend segment; simultaneously, the free end of the outer coil is bent using the first support block and the first outer bend block to form the first inner bend segment; simultaneously, the free end of the outer coil is bent using the first support block and the first outer bend block, the first outer bend seat includes the first support block and the first outer bend block, the bottom end of the first support block abuts against the upper surface of the base plate, the first outer bend block is integrally formed on the top end of the first support block, and the first outer bend block includes a second positioning surface, The first outer bending surface and the second outer bending surface, the angle between the second positioning surface and the first outer bending surface is an obtuse angle, the angle between the first outer bending surface and the second outer bending surface is an obtuse angle, and a first outer bending fillet is provided between the second positioning surface and the first outer bending surface, and a second outer bending fillet is provided between the first outer bending surface and the second outer bending surface. The enameled wire extending from the outer coil passes through the first outer bending fillet, the first outer bending surface, and the second outer bending surface in sequence, and the straight enameled wire is bent into the first outer bending segment and the second outer bending segment in sequence.

[0017] A5: The first clamping block is fixed to the side wall of the first inner bending seat. The first clamping block is detachably connected to the first positioning surface on the first inner bending seat. The first clamping block has a first clearance hole on the side facing the first positioning surface. The first clearance hole extends in the horizontal direction and both ends of the first clearance hole are open. The first clamping block and the first inner bending seat have a positioning function for the bent enameled wire.

[0018] By adopting the above technical solution, the first connecting block, the first positioning post, the first positioning ring, and the first outer bending seat are fixed on the base plate. The inner coil is accurately positioned using the annular positioning cavity formed by the first positioning post and the first positioning ring. The connecting wire is properly placed using the accommodating cavity. After the double-layer inductor coil is placed and positioned, the first inner bending seat is fixed. The inner coil is bent to form the first inner bending segment using the inner bending radius and the first inner bending channel. At the same time, the free end of the outer coil is bent using the first bearing block and the first outer bending block with a specific angle and bending radius to form the first outer bending segment and the second outer bending segment. Finally, the first clamping block is fixed, and its first clearance hole cooperates with the first inner bending seat to position the bent enameled wire. This achieves precise bending and positioning of the inner and outer coil ends of the double-layer inductor coil, ensuring the accuracy of the bending shape and size. This lays a good foundation for the subsequent coil forming process and helps to improve the electromagnetic performance of the coil and the product quality.

[0019] Optional, the specific steps in step two are as follows:

[0020] B1: The inductor coil, after the initial bending process, is removed from the first bending fixture and rotated 180°, and then placed on the third positioning post. The bottom end of the inductor coil abuts against the upper surface of the second bearing block, and the inner wall of the inductor coil is tightly fitted with the outer wall of the third positioning post. The first inner bending section of the inductor coil is located in the first inner positioning channel, and the first and second outer bending sections abut against the upper surface of the side inner bending block. The third positioning surface of the positioning protrusion abuts against part of the outer outer wall of the coil, the first outer bending section abuts against the side wall of the fourth positioning surface, and the second outer bending section abuts against the side wall of the fifth positioning surface.

[0021] B2: The first inner bending segment is further bent using the second inner bending seat. Specifically, the free end of the first inner bending segment is further bent using the side inner bending block to form the second inner bending segment. The second inner bending segment is perpendicular to the first inner bending segment, and the length direction of the second inner bending segment is parallel to the axis direction of the inductor coil. The side wall of the second inner bending segment abuts against the side wall of the second inner bending seat and the side wall of the side inner bending block. The second inner bending segment is then further bent using the top inner bending block and the second inner bending channel to form the third inner bending segment. The third inner bending segment is located inside the second inner bending channel, and the third inner bending segment is perpendicular to the first inner bending segment. The third inner bending segment is also perpendicular to the second inner bending segment.

[0022] B3: The second outer bending segment is further bent using the second outer bending seat. Specifically, the second outer bending segment is further bent using the third outer bending fillet and the second outer bending block to obtain the third outer bending segment.

[0023] By adopting the above technical solution, the initially bent inductor coil is rotated 180° and precisely fitted onto the third positioning post. The inductor coil is then meticulously positioned using components such as the second bearing block, the side inner bending block, and the positioning protrusion, ensuring that the first inner bending segment, the first outer bending segment, and the second outer bending segment are in accurate positions. Subsequently, the first inner bending segment is further bent using the second inner bending seat, sequentially forming the mutually perpendicular second inner bending segment and the third inner bending segment. Simultaneously, the second outer bending segment is further bent using the second outer bending seat to obtain the third outer bending segment. This achieves further precise bending of the inner and outer coil ends of the inductor coil, making the coil end bending shape more consistent with the preset requirements. This helps improve the overall forming accuracy of the coil, ensures the electromagnetic performance of the coil and the stability of its connection with other components, and enhances the quality and reliability of the product.

[0024] Optional, the specific steps in step three are as follows:

[0025] C1: Place the formed inductor coil on the testing and calibration fixture, set the three positioning mechanisms between the inner coil and the outer coil in sequence, rotate the second positioning block to an appropriate angle so that the multiple inner coils are respectively located in the multiple arc-shaped grooves on one side wall of the second positioning block, the multiple outer coils are respectively located in the multiple arc-shaped grooves on the other side wall of the second positioning block, and the multiple second positioning blocks are evenly distributed along the circumference.

[0026] C2: Adjust the position of the positioning mechanism so that the positions of the multiple positioning protrusions correspond exactly to the positions of the multiple first through holes, and make the six positioning protrusions pass through the six first through holes respectively;

[0027] C3: Install the n-shaped brackets on the corresponding second positioning blocks respectively, so that each fourth positioning post passes through the corresponding first through hole, and each positioning protrusion passes through the first through hole and the second through hole in sequence. At the same time, the top of the second positioning block passes through the second positioning groove at the top of the n-shaped bracket.

[0028] C4: Observe whether the third inner bend of the bent inductor is located in the first detection channel of the first detection block, and whether the second outer bend is located in the second detection channel of the second detection block. If both are located, it means that the bent inductor has met the bending standard.

[0029] By adopting the above technical solution, the formed inductor coil is placed in the testing and calibration fixture. Three positioning mechanisms are precisely positioned between the inner and outer coils. The second positioning block is rotated so that the inner and outer coils are respectively embedded in the arc-shaped grooves on its side walls. By adjusting the position of the positioning mechanism, the positioning protrusion passes through the first through hole of the inductor coil. Then, the n-shaped bracket is installed on the second positioning block, so that the positioning protrusion further passes through the second through hole and the top of the second positioning block is embedded in the second positioning groove of the n-shaped bracket. This achieves stable positioning of the inductor coil. Finally, by observing whether the third inner bending section is located in the first testing channel and whether the second outer bending section is located in the second testing channel, it is possible to accurately determine whether the bent inductor coil meets the bending standard. This achieves accurate detection of the bending shape and size of the inductor coil, effectively ensuring the forming quality of the coil, reducing the product defect rate, and improving production efficiency and product quality.

[0030] Optionally, the first bending fixture includes a first positioning seat, a first inner bending seat, and a first outer bending seat. The first positioning seat includes a first base plate, a first connecting block, a first positioning post, and a first positioning ring. The first connecting block is fixed to the surface of the first base plate, and the first positioning post and the first positioning ring are both fixed to the surface of the first connecting block. An annular positioning cavity for positioning the inner coil is formed between the first positioning post and the first positioning ring. A receiving cavity for accommodating the connecting wire is opened on the first positioning ring. The first inner bending seat is fixed to the top of the first positioning post and is used to perform preliminary bending of the enameled wire extending from the top of the inner coil. The first outer bending seat is fixed to the upper surface of the first base plate and is used to perform preliminary bending of the enameled wire extending from the top of the outer coil.

[0031] By adopting the above technical solution, a first connecting block is set on the first base plate, and a first positioning post and a first positioning ring are fixed on its surface to form an annular positioning cavity for accurately positioning the inner coil and a cavity for accommodating the connecting wire, thereby ensuring the accuracy and stability of the double-layer inductor coil placement. At the same time, the first inner bending seat is fixed to the top of the first positioning post, which can perform preliminary bending of the enameled wire extending from the top of the inner coil, while the first outer bending seat fixed to the upper surface of the first base plate performs preliminary bending of the enameled wire extending from the top of the outer coil. This allows the bending operations of the inner and outer coils to be performed independently and accurately, effectively ensuring the shape and dimensional accuracy of the preliminary bending of the inductor coil end, laying a good foundation for subsequent bending and forming processes, and helping to improve the overall forming quality and electromagnetic performance of the inductor coil.

[0032] Optionally, the first inner bending seat includes a first positioning surface and an inner bending surface; an inner bending radius is provided between the first positioning surface and the inner bending surface, a first inner bending channel is opened on the inner bending surface, a first clamping block is detachably connected to the first positioning surface, a first clearance hole is opened on the side of the first clamping block facing the first positioning surface, and both ends of the first clearance hole are open.

[0033] By adopting the above technical solution, the first inner bending seat provides a precise bending path for the enameled wire extending from the top of the inner coil by setting a first positioning surface and an inner bending surface, and setting an inner bending radius and a first inner bending channel between them, ensuring the smoothness and accuracy of the bending process. At the same time, the inner bending radius can reduce damage to the enameled wire during bending. The first clamping block detachably connected to the first positioning surface and its first clearance hole can play a good role in positioning and fixing the bent enameled wire, preventing its displacement, further ensuring the stability of the inner coil bending shape and size, and helping to improve the forming quality and electromagnetic performance of the inductor coil.

[0034] Optionally, the second bending fixture includes a second positioning seat, a second inner bending seat, and a second outer bending seat; the second positioning seat includes a second base plate, a second positioning post, a second bearing block, a third positioning post, and a first positioning block, used to position the inductor coil; the second inner bending seat includes a fixing block, a side inner bending block, and a top inner bending block, used to further bend the first inner bending segment; the second outer bending seat includes a third bearing block and a positioning protrusion, used to further bend the second outer bending segment.

[0035] By adopting the above technical solution, the second bending fixture, through components such as the second base plate, second positioning post, second bearing block, third positioning post, and first positioning block in the second positioning seat, achieves precise positioning of the inductor coil, providing a stable foundation for subsequent bending operations. The second inner bending seat, with the synergistic effect of the fixing block, the side inner bending block, and the top inner bending block, further bends the first inner bending section to form a bending shape that meets the requirements. The second outer bending seat, using the third bearing block and the positioning protrusion, further bends the second outer bending section. This allows for efficient and precise completion of the further bending process at the end of the inductor coil, effectively ensuring the accuracy of the bending shape and size of the inductor coil, thereby improving the forming quality and electromagnetic performance of the inductor coil and meeting production requirements.

[0036] Optionally, a slot is provided at the center of the second bearing block, and a slot is fixedly provided on the third positioning post, with the slot being inserted into the slot.

[0037] By adopting the above technical solution, a plug-in groove is opened in the center of the second bearing block, and a plug-in post is fixedly installed on the third positioning post to plug into it. This achieves precise connection and positioning between the second bearing block and the third positioning post. This plug-in method is not only simple in structure and easy to install, but also can effectively ensure the relative positional accuracy between the two, thereby ensuring the positioning accuracy of the inductor coil on the second bending fixture. This provides a stable and reliable foundation for further bending operations on the end of the inductor coil, and helps to improve the quality and efficiency of inductor coil bending.

[0038] Optionally, the detection and calibration fixture includes a third base plate and multiple positioning mechanisms. Each positioning mechanism includes a second positioning block, a fixed base, and an n-shaped bracket. The fixed base has multiple first through holes. A positioning post assembly is provided on the third base plate corresponding to the position of each fixed base. The positioning post assembly includes multiple positioning protrusions that pass sequentially through the first through holes on the fixed base. A second connecting block is fixed to the n-shaped bracket, and a fourth positioning post is fixed to the second connecting block. The fourth positioning post passes through the corresponding first through hole, and the positioning protrusion further passes through the fourth positioning post. The second positioning block passes through the second positioning groove at the top of the n-shaped bracket. Multiple arc-shaped grooves are provided on both opposite sidewalls of the second positioning block for positioning the inner coil and outer coil respectively.

[0039] By adopting the above technical solution, the testing and calibration fixture, through the cooperation of the third base plate and multiple positioning mechanisms, achieves initial positioning using the first through hole on the fixed seat and multiple positioning protrusions of the positioning post assembly on the third base plate. The fourth positioning post on the n-shaped bracket further passes through the first through hole, and the positioning protrusion passes through the fourth positioning post, enhancing the stability of the positioning. At the same time, the second positioning block passes through the second positioning groove at the top of the n-shaped bracket, and the arc-shaped grooves on its two opposite side walls accurately position the inner coil and the outer coil, respectively. This multi-layer positioning structure ensures the accurate placement of the inductor coil on the testing and calibration fixture, providing a reliable guarantee for subsequent accurate testing of whether the bending shape and size of the inductor coil meet the standards, which helps to improve testing efficiency and product quality, and reduce the product defect rate.

[0040] Optionally, a first detection block and a second detection block are also fixedly installed on the third base plate. The first detection block has a first detection channel and the second detection block has a second detection channel, which are used to detect whether the bent inductor coil meets the bending standard.

[0041] By adopting the above technical solution, a first detection block and a second detection block are fixedly set on the third base plate, and a first detection channel and a second detection channel are respectively opened on the first detection block and the second detection block. After the inductor coil is accurately positioned by the positioning mechanism, the first detection channel and the second detection channel can be used to intuitively and accurately detect whether the third inner bending section of the inner coil of the bent inductor coil is in the correct position and whether the second outer bending section of the outer coil meets the requirements. This allows for the determination of whether the inductor coil meets the bending standard, making the detection process more convenient, efficient and accurate. It can promptly detect inductor coils that do not meet the standard, which helps to improve product quality and production efficiency and reduce the defect rate caused by non-conforming bending.

[0042] In summary, this application includes at least one of the following beneficial technical effects:

[0043] 1. The inductor coil forming process involves first using a first bending fixture to initially bend the ends of the double-layer coil, then using a second bending fixture to further bend it to the preset shape, and finally using a testing and correction fixture to correct the bent coil ends to ensure that their shape meets the forming requirements. This entire process solves the problem of inaccurate coil end bending in related technologies, ensures the electromagnetic performance of the coil and the stability of its connection with other components, and reduces the product defect rate through effective correction methods, saving production costs and improving production efficiency and product quality.

[0044] 2. The first inner bending seat provides a precise bending path for the inner coil enameled wire through the first positioning surface, inner bending surface, inner bending radius, and first inner bending channel, reducing damage to the enameled wire. The first clamping block can position and fix the bent enameled wire, ensuring the stability of the inner coil's bending shape and size. The first outer bending seat bends the free end of the outer coil through a specific structure, realizing precise bending and positioning of the inner and outer coil ends of the double-layer inductor coil. This ensures the accuracy of the bending shape and size, lays a good foundation for subsequent coil forming processes, and helps improve the electromagnetic performance of the coil and product quality.

[0045] 3. The second inner bending seat and the second outer bending seat further bend the first inner bending segment and the second outer bending segment, respectively. With a clear division of labor and a reasonable structure, they can efficiently and accurately complete the further bending process at the end of the inductor coil, effectively ensuring the accuracy of the inductor coil's bent shape and dimensions, thereby improving the forming quality and electromagnetic performance of the inductor coil and meeting production requirements. The insertion and connection between the second bearing block and the third positioning post is simple in structure and convenient in installation, effectively ensuring the relative positional accuracy between them. This ensures the accurate positioning of the inductor coil on the second bending fixture, contributing to improved quality and efficiency of inductor coil bending. Attached Figure Description

[0046] Figure 1 This is a flowchart of the forming process of the inductor coil in the embodiments of this application.

[0047] Figure 2 This is a schematic diagram of the structure of the inductor coil in an embodiment of this application.

[0048] Figure 3 This is a schematic diagram of the inductor coil and the first bending fixture in an embodiment of this application.

[0049] Figure 4 This is a structural schematic diagram of the first bending fixture in the embodiments of this application from another perspective.

[0050] Figure 5 This application provides a schematic diagram of the structure of the inductor coil and the second bending fixture in an embodiment.

[0051] Figure 6This application provides a schematic diagram of the second bending fixture from another perspective in its embodiments.

[0052] Figure 7 This application provides a schematic diagram of the assembly relationship between the second positioning post and the third positioning post in an embodiment.

[0053] Figure 8 This application provides a schematic diagram of the structure of the second inner bending seat and the second outer bending seat in the embodiments of this application.

[0054] Figure 9 This application provides a schematic diagram of the structure of the second outer bending seat in an embodiment.

[0055] Figure 10 A schematic diagram of the structure of the inductor coil and positioning mechanism in the application embodiment.

[0056] Figure 11 A schematic diagram of the structure of the inductor coil and the detection and calibration fixture in the application embodiment.

[0057] Figure 12 A schematic diagram of the detection and calibration fixture in the application embodiment.

[0058] Figure 13 A half-sectional view of the positioning mechanism in the application embodiment.

[0059] Explanation of reference numerals in the attached figures:

[0060] 0. Inductor coil; 01. Inner coil; 011. First inner bend section; 012. Second inner bend section; 013. Third inner bend section; 02. Outer coil; 021. First outer bend section; 022. Second outer bend section; 023. Third outer bend section; 03. Connecting wire; 1. First positioning seat; 11. First base plate; 12. First connecting block; 13. First positioning post; 131. First positioning groove; 14. First positioning ring; 141. Accommodating cavity; 15. Positioning cavity; 2. First inner bend seat; 21. First positioning... 22. Inner bend surface; 23. Inner bend fillet; 24. First inner bend channel; 25. First clamping block; 26. First clearance hole; 3. First outer bend seat; 31. First bearing block; 32. First outer bend block; 321. Second positioning surface; 322. First outer bend surface; 323. Second outer bend surface; 324. First outer bend fillet; 325. Second outer bend fillet; 4. Second positioning seat; 41. Second base plate; 42. Second positioning post; 43. Second bearing block; 431. Insertion groove; 44. Third positioning post; 441, insertion post; 45, first positioning block; 451, first inner positioning channel; 452, first clearance groove; 46, first limiting part; 47, second clamping block; 5, second inner bending seat; 51, fixing block; 52, side inner bending block; 53, top inner bending block; 54, second inner bending channel; 6, second outer bending seat; 61, third bearing block; 62, positioning protrusion; 621, third positioning surface; 622, fourth positioning surface; 623, fifth positioning surface; 63, second outer bending block; 64 7. Third outer bend rounded corner; 8. Third base plate; 9. Positioning mechanism; 10. Second positioning block; 11. Arc-shaped groove; 12. Fixing seat; 13. Fixing groove; 14. First through hole; 15. N-shaped bracket; 16. Second connecting block; 17. Fourth positioning post; 18. Second through hole; 19. Second positioning groove; 20. Positioning post assembly; 21. Positioning protrusion; 22. First detection block; 33. First detection channel; 44. Second detection channel; 55. Second detection channel; 66. Second clearance groove; 77. Second detection channel; 88. Third outer bend rounded corner; 89. Third base plate; 10. Positioning mechanism; 11. Second positioning block; 12. Arc-shaped groove; 13. Second positioning groove; 14. Second positioning groove; 15. Second positioning groove; 16. Second detection channel; 78. Third outer bend rounded corner; 89. Third base plate; 17. Positioning mechanism; 18. Second positioning block; 19. Second positioning block; 100. Second clearance groove; 101. Second detection channel; 102. Second detection channel; 103. Third outer bend rounded corner; 104. Third outer base plate; 105. Positioning mechanism; 106. Second positioning block; 107. Second outer positioning groove; 102. Second detection channel; 108. Third outer bend rounded corner; 109. Third outer base plate; 100. Third outer base plate; 101. Positioning mechanism; 102. Third outer positioning groove; 103. Third outer base plate; 104. Third outer base plate; 105. Third outer base plate; 106. Third outer base plate; 107. Third outer base plate; 108. Third outer base plate; 109. Third outer base plate; 100. Third outer Detailed Implementation

[0061] The following is in conjunction with the appendix Figure 1-13 This application will be described in further detail.

[0062] The terminology used in this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. Unless otherwise defined, the technical or scientific terms used in this application should have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms "first," "second," and similar terms used in this application do not indicate any order, quantity, or importance, but are merely used to distinguish different components.

[0063] This application provides an inductor coil forming process, referring to... Figure 1 and Figure 2 The inductor coil forming process includes a preliminary bending process, a precision bending process, and a correction process. The inductor coil 0 includes an inner coil 01 and an outer coil 02 located outside the inner coil 01. The outer coil 02 and the inner coil 01 are formed by bending the same enameled wire, and the outer coil 02 and the inner coil 01 form a concentric circle structure. The outer coil 02 and the inner coil 01 are connected by a connecting wire 03 to enhance the induction effect.

[0064] Reference Figure 1 The process involves first performing a preliminary bending process to bend the ends of the double-layer inductor coil to be formed, followed by a precision bending process to achieve the preset bending shape, and finally a correction process to ensure that the shape of the coil ends meets the forming requirements. This achieves the effects of improving the space utilization of the inductor coil, the stability of electrical connections, and production efficiency. This is because precise bending and correction allow the coil ends to adapt to complex spatial layouts, ensure the stability of connections with other components, reduce manual intervention, and improve production efficiency.

[0065] Reference Figure 2 , Figure 3 and Figure 4 Specifically, the preliminary bending process requires a first bending fixture, which includes a first positioning seat 1. The first positioning seat 1 includes a first base plate 11, a first connecting block 12, a first positioning post 13, and a first positioning ring 14. The first connecting block 12 is fixed to the surface of the first base plate 11 by multiple bolts. The first positioning post 13 and the first positioning ring 14 are both fixed to the surface of the first connecting block 12 by bolts. An annular positioning cavity 15 for positioning the inner coil 01 is formed between the first positioning post 13 and the first positioning ring 14. The first positioning ring 14 also has a receiving cavity 141 for accommodating the connecting wire 03. The length direction of the receiving cavity 141 is the same as the length direction of the first positioning ring 14, and both ends of the receiving cavity 141 are open. This receiving cavity 141 can effectively prevent the connecting wire 03 from being squeezed or interfered with during the bending process, ensuring the integrity and electrical performance of the connecting wire 03. The first positioning post 13 is located inside the first positioning ring 14. The axis of the first positioning post 13 coincides with that of the first positioning ring 14. The diameter of the first positioning post 13 is smaller than the inner diameter of the first positioning ring 14. When the operator places the inductor coil 0 on the first positioning seat 1, the inner coil 01 is located in the annular positioning cavity 15, and the outer coil 02 is sleeved on the first positioning ring 14. The inner sidewall of the outer coil 02 abuts against the inner sidewall of the first positioning ring 14. The ends of the inner coil 01 and the outer coil 02 abut against the upper surface of the first connecting block 12. At the same time, the connecting wire 03 is located in the accommodating cavity 141.

[0066] Reference Figure 3 and Figure 4The first positioning post 13 is fixedly provided with a first inner bending seat 2 at its top end, and the first base plate 11 is fixedly provided with a first outer bending seat 3 on its upper surface. The first inner bending seat 2 is used to perform preliminary bending of the enameled wire extending from the top end of the inner coil 01, and the first outer bending seat 3 is used to perform preliminary bending of the enameled wire extending from the top end of the outer coil 02.

[0067] Reference Figure 3 The first positioning post 13 has a first positioning groove 131 at its top. The outer wall of the first inner bending seat 2 abuts against the inner wall of the first positioning groove 131. The first inner bending seat 2 is fixed to the top of the first positioning post 13 by bolts, or it can be fixed by magnetic attraction. The first inner bending seat 2 includes a first positioning surface 21 and an inner bending surface 22. Both the first positioning surface 21 and the inner bending surface 22 are located on the side wall of the first inner bending seat 2 away from the first positioning post 13. The inner bending surface 22 is used to bend the enameled wire extending from the inner coil 01. The angle between the first positioning surface 21 and the inner bending surface 22 is an obtuse angle, and an inner bending radius 23 is provided between the first positioning surface 21 and the inner bending surface 22. The inner bending radius 23 can make the stress on the enameled wire more uniform during the bending process and prevent the enameled wire from breaking due to excessive bending.

[0068] Reference Figure 3 Furthermore, a first inner bending channel 24 is formed on the inner bending surface 22, and the length direction of the first inner bending channel 24 is parallel to the upper surface of the first base plate 11. A first clamping block 25 can also be detachably connected to the first positioning surface 21. A first clearance hole 26 is formed on the side of the first clamping block 25 facing the first positioning surface 21. The first clearance hole 26 extends in the horizontal direction and both ends of the first clearance hole 26 are open.

[0069] Reference Figure 2 and Figure 3 When the inductor coil 0 is placed on the first positioning seat 1, the enameled wire extending from the inner coil 01 is first bent through the inner bending rounded corner 23 so that the bent enameled wire is located in the first inner bending channel 24. Then, the first clamping block 25 is fixed on the first inner bending seat 2. The first clamping block 25 and the first inner bending seat 2 have a positioning function for the bent enameled wire, thereby realizing the initial bending of the enameled wire extending from the inner coil 01, thus forming the first inner bending segment 011. The length direction of the first inner bending segment 011 is perpendicular to the axial direction of the inductor coil 0.

[0070] Reference Figure 3 and Figure 4The first outer bending seat 3 is fixed to the upper surface of the base plate. The specific fixing method can be bolt connection, magnetic connection, or integral molding. Further, the first outer bending seat 3 includes a first bearing block 31 and a first outer bending block 32. The bottom end of the first bearing block 31 abuts against the upper surface of the base plate, and the first outer bending block 32 is integrally formed on the top end of the first bearing block 31. The first outer bending block 32 includes a second positioning surface 321, a first outer bending surface 322, and a second outer bending surface 323. The second positioning surface 321 is located on the side of the first outer bending block 32 close to the first positioning post 13. The angle between the second positioning surface 321 and the first outer bending surface 322 is an obtuse angle, and the angle between the first outer bending surface 322 and the second outer bending surface 323 is also an obtuse angle. A first outer bending fillet 324 is provided between the second positioning surface 321 and the first outer bending surface 322, and a second outer bending fillet 325 is provided between the first outer bending surface 322 and the second outer bending surface 323. The first outer bending fillet 324 and the second outer bending fillet 325 enable the enameled wire extending from the outer coil 02 to bend more smoothly, reducing the deformation and damage of the enameled wire.

[0071] Reference Figure 3 and Figure 4 When the inductor coil 0 is mounted on the first positioning seat 1, the enameled wire extending from the outer coil 02 extends horizontally, and the top of the first bearing block 31 just abuts against the bottom of the enameled wire. When it is necessary to bend the enameled wire extending from the outer coil 02, the enameled wire extending from the outer coil 02 will pass through the first outer bending radius 324, the first outer bending surface 322, and the second outer bending surface 323 in sequence, thereby bending the straight enameled wire into the first outer bending segment 021 and the second outer bending segment 022 in sequence. The length direction of the first outer bending segment 021 is perpendicular to the axis of the inductor coil 0, and the length direction of the second outer bending segment 022 is parallel to the axis of the inductor coil 0.

[0072] Reference Figure 3 and Figure 4 Regarding the bending sequence, the first inner bending seat 2 or the first outer bending seat 3 can be used first, or both can be bent simultaneously. Through the above preliminary bending process, the initial bending of the end of the inductor coil 0 can be achieved, laying the foundation for the subsequent precision bending and correction processes, thereby improving the space utilization, electrical connection stability and production efficiency of the inductor coil 0.

[0073] Reference Figure 5 and Figure 6Specifically, the second bending fixture used in the precision bending process includes a second positioning seat 4, which comprises a second base plate 41, a second positioning post 42, a second bearing block 43, a third positioning post 44, and a first positioning block 45. The axis of the second positioning post 42 extends vertically, and its bottom end is fixedly connected to the upper surface of the second base plate 41. The second bearing block 43 is integrally formed on the top of the second positioning post 42, and its horizontal cross-section is semi-circular. The axis of the second bearing block 43 coincides with the axis of the second positioning post 42. A insertion groove 431 is provided in the center of the second bearing block 43, and an insertion post 441 is integrally formed on the bottom end of the third positioning post 44. The insertion post 441 and the insertion groove 431 are inserted into each other, thereby fixing the third positioning post 44 to the upper surface of the second bearing block 43. This insertion method makes the installation and disassembly of the third positioning post 44 more convenient, facilitating subsequent maintenance and replacement.

[0074] Reference Figure 5 , Figure 6 and Figure 8 The first positioning block 45 is fixed to the upper surface of the second base plate 41. An arc-shaped first clearance groove 452 is formed on the side wall of the first positioning block 45 near the second positioning post 42, and the second positioning post 42 is located in the first clearance groove 452. A first inner positioning channel 451 is formed on the upper surface of one end of the first positioning block 45. Both ends of the first inner positioning channel 451 are open, and the shape of the first inner positioning channel 451 is adapted to the shape of the first inner bending section 011.

[0075] Reference Figure 5 , Figure 6 and Figure 8 Meanwhile, the upper surface of the first positioning block 45 integrally forms a first limiting part 46, and the side wall of the first limiting part 46 abuts against the side wall of the first inner bending section 011, increasing the stability of the first inner bending section 011 placed in the first inner positioning channel 451. The upper surface of the first limiting part 46 can also be detachably connected to a second clamping block 47. After the first outer bending section 021 is placed in the first inner positioning channel 451, the second clamping block 47 is then fixed to the first limiting part 46. The second clamping block 47 and the first limiting part 46 have a clamping and fixing effect on the first inner bending section 011 in the first inner positioning channel 451. This clamping and fixing method can ensure that the first inner bending section 011 remains stable during subsequent bending processes and avoid displacement.

[0076] Reference Figure 5 , Figure 6 and Figure 8The second bending fixture also includes a second inner bending seat 5, which includes a fixing block 51. The fixing block 51 is fixed to the upper surface of the first positioning block 45 by bolts. The side wall of the fixing block 51 is integrally formed with a side inner bending block 52. The lower surface of the side inner bending block 52 abuts against the upper surface of the first limiting part 46, and the lower surface of the side inner bending block 52 abuts against the top of the first inner bending segment 011. The free end of the first inner bending segment 011 is further bent using the side inner bending block 52 to form a second inner bending segment 012. The second inner bending segment 012 is perpendicular to the first inner bending segment 011, and the length direction of the second inner bending segment 012 is parallel to the axial direction of the inductor coil 0. The side wall of the second inner bending segment 012 abuts against both the side wall of the second inner bending seat 5 and the side wall of the side inner bending block 52.

[0077] Reference Figure 2 , Figure 5 and Figure 8 The upper surface of the fixing block 51 is integrally formed with a top inner bending block 53, while the upper surface of the side inner bending block 52 is also provided with a second inner bending channel 54. The side wall of the top inner bending block 53 is adapted to the second inner bending channel 54. The second inner bending segment 012 is further bent using the top inner bending block 53 and the second inner bending channel 54 to form a third inner bending segment 013. At this time, the third inner bending segment 013 is located inside the second inner bending channel 54. The formed third inner bending segment 013 is not only perpendicular to the first inner bending segment 011, but also perpendicular to the second inner bending segment 012. This multi-segment bending structure allows the inductor coil 0 to better adapt to complex spatial layouts and improve space utilization.

[0078] Reference Figure 3 , Figure 8 and Figure 9 The second bending fixture also includes a second outer bending seat 6. The second outer bending seat 6 includes a third bearing block 61 and a positioning protrusion 62. The third bearing block 61 is integrally formed on the upper surface of the other end of the first positioning block 45. The positioning protrusion 62 is integrally formed on the upper surface of the third bearing block 61. The positioning protrusion 62 includes a third positioning surface 621, a fourth positioning surface 622 and a fifth positioning surface 623 arranged in sequence. The third positioning surface 621 is used to position part of the outer coil 02, the fourth positioning surface 622 is used to position the first outer bending segment 021, and the fifth positioning surface 623 is used to position the second outer bending segment 022.

[0079] Reference Figure 5 , Figure 6 , Figure 8 and Figure 9After the inductor coil 0 is bent by the first bending fixture, it is removed from the fixture and rotated 180° before being placed on the third positioning post 44 of the second bending fixture used in the precision bending process. The bottom end of the inductor coil 0 abuts against the upper surface of the second support block 43, while the inner wall of the inductor coil 0 is tightly fitted against the outer wall of the third positioning post 44. Through the combined action of the second support block 43 and the third positioning post 44, the inductor coil 0 is precisely positioned. During the positioning process, the first inner bending segment 011 of the inductor coil 0, formed by the preliminary bending process, is precisely located within the first inner positioning channel 451 on the upper surface of the first positioning block 45, which has a matching shape, ensuring that the position of the first inner bending segment 011 is accurate and stable. Simultaneously, the first outer bending segment 021 and the second outer bending segment 022 formed by the initial bending will abut against the upper surface of the side inner bending block 52. Furthermore, the positioning protrusion 62 on the third bearing block 61, integrally formed on the upper surface of the other end of the first positioning block 45, will have its third positioning surface 621 abut against part of the outer wall of the outer coil 02. The first outer bending segment 021 abuts against the side wall of the fourth positioning surface 622, and the second outer bending segment 022 abuts against the side wall of the fifth positioning surface 623. Through the above-mentioned multi-faceted positioning and coordination, it is possible to ensure that the inductor coil 0 is accurately positioned and stably placed after being flipped and fitted onto the second bending fixture, guaranteeing the positional accuracy and stability of the inductor coil 0 in subsequent processing steps, effectively avoiding the impact of positional offset or shaking on processing quality, and providing a reliable positioning basis for subsequent precision bending operations.

[0080] Reference Figure 5 and Figure 6 The first positioning block 45 has a second outer bending block 63 integrally formed on the side wall opposite to the second positioning seat 4. The second outer bending block 63 is cuboid in shape, and a third outer bending fillet 64 is provided between the third bearing block 61 and the second outer bending block 63. Using the third outer bending fillet 64 and the second outer bending block 63, the second outer bending segment 022 can be further bent to obtain the third outer bending segment 023. The third outer bending segment 023 can further optimize the shape of the inductor coil 0 and improve its electrical performance.

[0081] Reference Figure 2 , Figure 5 and Figure 6 Regarding the bending sequence of the inductor coil 0 by the second bending fixture, the first inner bending segment 011 can be further bent using the second inner bending seat 5 to form the second inner bending segment 012, or the second outer bending seat 6 can be further bent using the second outer bending segment 022 to form the third outer bending segment 023, or both can be bent simultaneously.

[0082] Reference Figure 10 , Figure 11 and Figure 12 The testing and calibration fixture includes a third base plate 7 and a positioning mechanism 8. In this embodiment, there are three positioning mechanisms 8. Each positioning mechanism 8 includes a second positioning block 81 and a fixing seat 82. The fixing seat 82 has a through fixing groove 821 in its center. The bottom end of the second positioning block 81 passes through the fixing groove 821 and is fixedly connected to the fixing seat 82. Both side walls of the second positioning block 81 have multiple arc-shaped grooves 811, which are spaced apart along the length of the second positioning block 81. After the coil is formed, the operator sequentially places three positioning mechanisms 8 between the inner coil 01 and the outer coil 02. Then, the second positioning block 81 is rotated at an appropriate angle, so that multiple inner coils 01 are respectively located in multiple arc-shaped grooves 811 on one side wall of the second positioning block 81, and multiple outer coils 02 are respectively located in multiple arc-shaped grooves 811 on the other side wall of the second positioning block 81. At the same time, the multiple second positioning blocks 81 are evenly distributed circumferentially, thereby initially setting multiple fixing mechanisms between the inner coil 01 and the outer coil 02. The arc-shaped grooves 811 can ensure the accurate positioning of the inner coil 01 and the outer coil 02, improving the accuracy of the detection.

[0083] Reference Figure 12 and Figure 13 The upper surface of the third base plate 7 is provided with three positioning post assemblies 84, which are evenly distributed circumferentially and correspond one-to-one with the positioning mechanism 8. Each positioning post assembly 84 includes two positioning protrusions 841, both extending vertically, and their bottom ends are fixedly connected to the third base plate 7. Correspondingly, the upper surface of each fixing seat 82 has two through holes 822, which are symmetrically distributed on opposite sides of the fixing seat 82. The fixing post corresponds one-to-one with the positioning protrusions 841, and the diameter of the first through hole 822 is larger than the diameter of the positioning protrusion 841. Then, by adjusting the position of one or two second positioning blocks 81 circumferentially according to the position of the positioning assembly, the position of the six positioning protrusions 841 corresponds exactly to the position of the six first through holes 822. At the same time, the six positioning protrusions 841 pass through the six first through holes 822 respectively. This positioning method can ensure the stability of the inductor coil 0 during the detection process and avoid the detection results being affected by shaking.

[0084] Reference Figure 11 , Figure 12 and Figure 13The positioning mechanism 8 also includes three n-shaped brackets 83. Each n-shaped bracket 83 has a second connecting block 831 integrally formed on both sides, and a fourth positioning post 832 integrally formed on the lower surface of each second connecting block 831. Each second connecting block 831 has a second through hole 833 on its upper surface, with the bottom end of the second through hole 833 penetrating the fourth positioning post 832. Simultaneously, the top of the n-shaped bracket 83 also has a second positioning groove 834 for inserting the second positioning block 81. Then, the staff installs the n-shaped bracket 83 onto the corresponding second positioning block 81, so that each fourth positioning post 832 passes through the corresponding first through hole 822. At this time, the outer side of the fourth positioning post 832 is just in contact with the inner sidewall of the first through hole 822. Meanwhile, each positioning protrusion 841 passes through the first through hole 822 and the second through hole 833 in sequence. At the same time, the top of the second positioning block 81 passes through the second positioning groove 834 at the top of the n-shaped bracket 83. The n-shaped bracket 83 and the fourth positioning post 832 can further improve the stability and positioning accuracy of the detection and calibration fixture.

[0085] Reference Figure 11 and Figure 12 Meanwhile, a first detection block 9 and a second detection block 10 are fixedly installed on the upper surface of the third base plate 7. The upper surface of the first detection block 9 has a first detection channel 91, and the side wall of the second detection block 10 has a second clearance groove 101. The bottom of the second clearance groove 101 has a second detection channel 102. When the third inner bending section 013 of the bent inductor coil 0 is located in the first detection channel 91 and the second outer bending section 022 is located in the second detection channel 102, it indicates that the bent inductor coil 0 has met the bending standard. This detection method can intuitively judge the bending quality of the inductor coil 0.

[0086] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A forming process for an inductor coil (0), characterized in that: Includes the following steps: Step 1: Use the first bending fixture to perform a preliminary bend on the ends of the double-layer coil; Step 2: Use the second bending fixture to further bend the initially bent coil end to achieve the preset bending shape; Step 3: Use a testing and calibration fixture to calibrate the ends of the bent coil to ensure that its shape meets the forming requirements; The specific steps in Step One are as follows: A1: The first connecting block (12), the first positioning post (13), the first positioning ring (14) and the first outer bending seat (3) are all fixed on the base plate. An annular positioning cavity (15) for positioning the inner coil (01) is formed between the first positioning post (13) and the first positioning ring (14). The first positioning ring (14) is also provided with a receiving cavity (141) for accommodating the connecting wire (03). A2: Place the double-layer inductor coil (0) on the first positioning seat (1), align the inner coil (01) with the annular positioning cavity (15), so that the inner coil (01) is sleeved on the first positioning post (13), so that the connecting line (03) is located in the accommodating cavity (141), and at the same time, sleeve the coil on the first positioning ring (14). A3: Fix the first inner bending seat (2) onto the first positioning post (13); A4: The inner coil (01) is bent using the inner bend fillet (23) and the first inner bend channel (24) to form the first inner bend segment (011); at the same time, the free end of the outer coil (02) is bent using the first bearing block (31) and the first outer bend block (32) to form the first inner bend segment (011); the first outer bend seat (3) includes the first bearing block (31) and the first outer bend block (32), the bottom end of the first bearing block (31) abuts against the upper surface of the base plate, the first outer bend block (32) is integrally formed on the top end of the first bearing block (31), the first outer bend block (32) includes the second positioning surface (321), the first outer bend surface (322) and the second outer bend surface (323), so The angle between the second positioning surface (321) and the first outer bending surface (322) is an obtuse angle, the angle between the first outer bending surface (322) and the second outer bending surface (323) is an obtuse angle, and a first outer bending fillet (324) is provided between the second positioning surface (321) and the first outer bending surface (322), and a second outer bending fillet (325) is provided between the first outer bending surface (322) and the second outer bending surface (323). The enameled wire extending from the outer coil (02) passes through the first outer bending fillet (324), the first outer bending surface (322), and the second outer bending surface (323) in sequence, and the straight enameled wire is bent into the first outer bending segment (021) and the second outer bending segment (022) in sequence. A5: The first clamping block (25) is fixed to the side wall of the first inner bending seat (2). The first clamping block (25) is detachably connected to the first positioning surface (21) on the first inner bending seat (2). The first clamping block (25) has a first clearance hole (26) on the side facing the first positioning surface (21). The first clearance hole (26) extends in the horizontal direction. Both ends of the first clearance hole (26) are open. The first clamping block (25) and the first inner bending seat (2) have a positioning function for the bent enameled wire.

2. The forming process of an inductor coil (0) according to claim 1, characterized in that: The specific steps in step two are as follows: B1: The inductor coil (0) after the initial bending process is removed from the first bending fixture and rotated 180°, and placed on the third positioning post (44), so that the bottom end of the inductor coil (0) abuts against the upper surface of the second bearing block (43), the inner side wall of the inductor coil (0) is tightly fitted with the outer side wall of the third positioning post (44), the first inner bending section (011) of the inductor coil (0) is located in the first inner positioning channel (451), the first outer bending section (021) and the second outer bending section (022) abut against the upper surface of the side inner bending block (52), the third positioning surface (621) of the positioning protrusion (62) abuts against part of the outer side wall of the outer coil (02), the first outer bending section (021) abuts against the side wall of the fourth positioning surface (622), and the second outer bending section (022) abuts against the side wall of the fifth positioning surface (623); B2: The first inner bending segment (011) is further bent using the second inner bending seat (5). Specifically, the free end of the first inner bending segment (011) is further bent using the side inner bending block (52) to form the second inner bending segment (012). The second inner bending segment (012) is perpendicular to the first inner bending segment (011), and the length direction of the second inner bending segment (012) is parallel to the axis direction of the inductor coil (0). The side wall of the second inner bending segment (012) simultaneously abuts against the side wall of the second inner bending seat (5) and the side wall of the side inner bending block (52). The second inner bending segment (012) is then further bent using the top inner bending block (53) and the second inner bending channel (54) to form the third inner bending segment (013). The third inner bending segment (013) is located exactly in the second inner bending channel (54). Inside, the third inner bend (013) is perpendicular to the first inner bend (011), and the third inner bend (013) is also perpendicular to the second inner bend (012). B3: The second outer bending segment (022) is further bent using the second outer bending seat (6), specifically: the second outer bending segment (022) is further bent using the third outer bending fillet (64) and the second outer bending block (63) to obtain the third outer bending segment (023).

3. The forming process of an inductor coil (0) according to claim 1, characterized in that: The specific steps in step three are as follows: C1: Place the formed inductor coil (0) on the testing and calibration fixture, and set the three positioning mechanisms (8) between the inner coil (01) and the outer coil (02) in sequence. Rotate the second positioning block (81) to an appropriate angle so that the multiple inner coils (01) are respectively located in the multiple arc-shaped grooves (811) on one side wall of the second positioning block (81), and the multiple outer coils (02) are respectively located in the multiple arc-shaped grooves (811) on the other side wall of the second positioning block (81), and the multiple second positioning blocks (81) are evenly distributed along the circumference. C2: Adjust the position of the positioning mechanism (8) so that the positions of the multiple positioning protrusions (841) correspond exactly to the positions of the multiple first through holes (822), and make the six positioning protrusions (841) pass through the six first through holes (822) respectively; C3: Install the n-shaped bracket (83) on the corresponding second positioning block (81) respectively, so that each fourth positioning post (832) passes through the corresponding first through hole (822) respectively, and each positioning protrusion (841) passes through the first through hole (822) and the second through hole (833) in sequence, while the top of the second positioning block (81) passes through the second positioning groove (834) at the top of the n-shaped bracket (83); C4: Observe whether the third inner bend (013) of the bent inductor coil (0) is located in the first detection channel (91) of the first detection block (9), and whether the second outer bend (022) is located in the second detection channel (102) of the second detection block (10). If both are located, it means that the bent inductor coil (0) has met the bending standard.

4. The forming process of an inductor coil (0) according to claim 1, characterized in that: The first bending fixture includes a first positioning seat (1), a first inner bending seat (2), and a first outer bending seat (3). The first positioning seat (1) includes a first base plate (11), a first connecting block (12), a first positioning post (13), and a first positioning ring (14). The first connecting block (12) is fixed to the surface of the first base plate (11). The first positioning post (13) and the first positioning ring (14) are both fixed to the surface of the first connecting block (12). The first positioning post (13) and the first positioning ring... (14) form an annular positioning cavity (15) for positioning the inner coil (01), and the first positioning ring (14) has a receiving cavity (141) for accommodating the connecting wire (03); the first inner bending seat (2) is fixed to the top of the first positioning post (13) for performing preliminary bending on the enameled wire extending from the top of the inner coil (01); the first outer bending seat (3) is fixed to the upper surface of the first base plate (11) for performing preliminary bending on the enameled wire extending from the top of the outer coil (02).

5. The forming process of an inductor coil (0) according to claim 4, characterized in that: The first inner bending seat (2) includes a first positioning surface (21) and an inner bending surface (22); an inner bending rounded corner (23) is provided between the first positioning surface (21) and the inner bending surface (22); a first inner bending channel (24) is opened on the inner bending surface (22); a first clamping block (25) is detachably connected to the first positioning surface (21); a first clearance hole (26) is opened on the side of the first clamping block (25) facing the first positioning surface (21); and both ends of the first clearance hole (26) are open.

6. The forming process of an inductor coil (0) according to claim 1, characterized in that: The second bending fixture includes a second positioning seat (4), a second inner bending seat (5), and a second outer bending seat (6); the second positioning seat (4) includes a second base plate (41), a second positioning post (42), a second bearing block (43), a third positioning post (44), and a first positioning block (45), for positioning the inductor coil (0); the second inner bending seat (5) includes a fixing block (51), a side inner bending block (52), and a top inner bending block (53), for further bending the first inner bending segment (011); the second outer bending seat (6) includes a third bearing block (61) and a positioning protrusion (62), for further bending the second outer bending segment (022).

7. The forming process of an inductor coil (0) according to claim 6, characterized in that: The second bearing block (43) has a center slot (431) and the third positioning post (44) is fixedly provided with a plug post (441), which is plugged into the slot (431).

8. The forming process of an inductor coil (0) according to claim 7, characterized in that: The testing and calibration fixture includes a third base plate (7) and multiple positioning mechanisms (8). The positioning mechanism (8) includes a second positioning block (81), a fixed seat (82), and an n-shaped bracket (83). The fixed seat (82) has multiple first through holes (822). The third base plate (7) is provided with a positioning post assembly (84) corresponding to the position of each fixed seat (82). The positioning post assembly (84) includes multiple positioning protrusions (841). The positioning protrusions (841) pass through the first through holes (822) on the fixed seat (82) in sequence. The n-shaped bracket (83) 3) A second connecting block (831) is fixed on the second connecting block (831), and a fourth positioning post (832) is fixed on the second connecting block (831). The fourth positioning post (832) passes through the corresponding first through hole (822), and the positioning protrusion (841) further passes through the fourth positioning post (832). The second positioning block (81) passes through the second positioning groove (834) at the top of the n-shaped bracket (83). Multiple arc-shaped grooves (811) are opened on the two opposite side walls of the second positioning block (81) for positioning the inner coil (01) and the outer coil (02) respectively.

9. The forming process of an inductor coil (0) according to claim 8, characterized in that: The third base plate (7) is also fixedly provided with a first detection block (9) and a second detection block (10). The first detection block (9) has a first detection channel (91) and the second detection block (10) has a second detection channel (102) for detecting whether the bent inductor coil (0) meets the bending standard.

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