Flat wire motor unwinding device and control method thereof

Abstract

The application discloses a flat wire motor unwinding device and a control method thereof, and relates to the technical field of wire forming for flat wire motor production, and comprises an unwinding device, a tensioning and monitoring device and a copper wire buffer device. The movable guide wheel is used for tensioning and real-time adjustment of copper wire tension. The unwinding belt is used for isolating the wire coil from the wire pulling component, and the tensile force borne by the copper wire is reduced by more than 30%. The diameter measuring sensor is used for real-time monitoring of the wire coil diameter, the PLC control cabinet is used for dynamic adjustment of the unwinding motor speed, the unwinding wire speed is matched with the unwinding belt wire speed, and constant tension is maintained. The copper wire buffer space is used for storing redundant copper wire through a multi-layer guide wheel structure, and the wire length PID closed-loop control of the unwinding belt and the wire pulling component is combined to realize continuous unwinding. The accumulated wire feeding length matching algorithm is used for smooth processing of signals, and the number of motor start-stop times is reduced by more than 50%, and the equipment service life is prolonged. The application provides key technical support for efficient and high-quality production of flat wire motors, and has remarkable economic benefits and industry popularization value.

Description

Technical Field

[0001] The present invention relates to the technical field of wire forming for flat wire motor production, and in particular to a flat wire motor unwinding device and a control method thereof. Background Art

[0002] With the rapid development of new energy vehicles, industrial automation, and other fields, flat wire motors have gradually become core components of drive systems due to their advantages such as high power density, high efficiency, and low noise. However, the manufacturing of flat wire motors places higher demands on the wire forming process, especially the copper wire unwinding process. Traditional flat wire motors mostly use a passive unwinding method, that is, the wire is directly pulled by the wire pulling component to unwind the wire. This has the following technical defects:

[0003] 1. Poor unwinding stability: Passive unwinding relies on the pulling force of the wire pulling component. The wire coil is easily affected by inertia or tension fluctuations, causing the copper wire to become loose or too tight, and even causing the wire to deform or break, affecting the subsequent forming accuracy.

[0004] 2. Low cycle efficiency: The traditional unwinding method has a delayed response and is difficult to match the cycle of high-speed wire forming equipment (such as 1.5 seconds / piece). Frequent starting and stopping causes large fluctuations in motor load and shortens equipment life.

[0005] 3. High risk of copper wire damage: The wire pulling component is directly coupled to the wire reel. During high-speed pulling, the copper wire is subjected to large tensile forces, which can easily cause microcracks or surface damage, reducing the reliability of the motor winding.

[0006] 4. Insufficient control accuracy: Traditional solutions lack real-time monitoring of the roll diameter and dynamic tension compensation mechanism. It is difficult to accurately match the unwinding speed with the pulling speed, resulting in accumulated line length errors and affecting the forming consistency.

[0007] To address these issues, existing technologies have attempted to introduce active unwinding mechanisms. However, these mechanisms often rely on single-motor drives or simple tension control, failing to effectively isolate the effects of wire pulling forces on the coil and remaining unsolved by the complexities of controlling copper wire buffering and speed synchronization. Therefore, there is an urgent need for an active unwinding device and control method that can achieve stable and continuous unwinding, minimize copper wire damage, and adapt to high-speed cycle requirements. Summary of the Invention

[0008] The object of the present invention is to provide a flat wire motor unwinding device and a control method thereof, so as to solve the problems of poor unwinding stability, low beat efficiency, high risk of copper wire damage, insufficient control accuracy, etc. in the copper wire unwinding method of the traditional flat wire motor proposed in the above background technology.

[0009] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a flat wire motor unwinding device, comprising an unwinding device, a tensioning and monitoring device, and a copper wire caching device arranged in sequence; the unwinding device comprises a horizontally arranged unwinding base plate and on its top surface, unwinding brackets are respectively arranged in mirror image near the middle of its left and right sides, and the top ends of the two unwinding brackets are jointly provided with a horizontal unwinding cross frame, and an unwinding mechanism is jointly provided through the unwinding bracket and the unwinding cross frame; the tensioning and monitoring device is arranged on the top surface of the unwinding base plate near the rear side, and comprises a fixed guide wheel portion arranged on the front side and a tensioning monitoring portion arranged on the rear side; the copper wire caching device comprises a cache bracket and on its top surface, a copper wire driving and conveying component is arranged near the left front side, and a copper wire caching space is arranged on the right side of the copper wire driving and conveying component.

[0010] Preferably, the unwinding base plate includes a rectangular unwinding base plate and a through hole and anchor bolts are respectively provided at its four corners; a base inclined plate with a triangular cross-section is provided at the front side of the unwinding base plate; the unwinding bracket includes a bracket base plate, and bracket uprights are vertically provided on the side close to each other on the top surfaces of the two bracket base plates, and two inclined plate reinforcement ribs are respectively provided between the outer side surfaces of the bracket uprights and the top surface of the bracket base plate; the unwinding cross frame includes a horizontally arranged cross frame plate, and the cross frame plate is respectively provided with a lifting motor through hole at the support uprights on both sides, two tensioning cylinder mounting holes are provided between the two lifting motor through holes, and a driving motor mounting hole is provided on the rear side between the two tensioning cylinder mounting holes; a wire coil diameter measuring sensor is provided on the bottom surface of the cross frame plate.

[0011] Base comprises support, castor, and frame upper is provided with guide rail, and support and conveyer frames movable end contact site are provided with recoil spring, and castor is arranged on the pin of base bottom four, to carry mobile handler location.

[0012] Preferably, the fixed guide wheel part includes a fixed guide wheel base plate arranged on the top surface of the unwinding base plate, a column fixing seat is respectively provided on the top surface of the fixed guide wheel base plate near both ends, a cylindrical column is vertically provided at the axis of the column fixing seat, a locking slider for lifting and moving is provided on the cylindrical column, a fixed guide wheel support plate is respectively provided on the side where the two locking sliders are close to each other, and a concave support groove is provided at the middle of the top of the two fixed guide wheel support plates and a fixed guide wheel is commonly provided.

[0013] Preferably, the tension monitoring part includes a guide wheel base plate arranged on the top surface of the unwinding base plate, and a column fixing seat is respectively provided on the top surface of the guide wheel base plate near both ends, a cylindrical column is vertically provided at the axis center of the column fixing seat, and a bracket mounting seat is provided at the top of the cylindrical column, and a bracket mounting seat is provided, and a bracket mounting base plate is horizontally provided on the top of the bracket mounting seat, and a bearing seat is provided on the top surface of the bracket mounting base plate, and the bearing seat is provided with a swing bracket through the bearing, and the two swing brackets are jointly provided with a swing plate, and two tensioning cylinders are provided on the top surface of the swing plate through the bracket, and the ends of the piston shafts of the two tensioning cylinders are jointly provided with movable guide wheels, and a laser rangefinder is provided on the swing plate through the bracket of the two tensioning cylinders.

[0014] Preferably, the cache bracket includes a bracket frame assembled with profiles, a bracket plate is provided on the top surface of the bracket frame, a copper wire driving and conveying component is provided on the top surface of the bracket plate near the left front side, and a copper wire cache space is provided on the right side of the copper wire driving and conveying component; a plurality of adjustment feet are provided on the bottom surface of the bracket frame, and fixed inclined feet are provided on the side walls of the bracket frame on the outside of the adjustment feet.

[0015] Preferably, the copper wire drive conveying component includes a rectangular copper wire drive frame, and multiple groups of mutually meshing wire transmission gears are arranged inside the copper wire drive frame, and one of the wire transmission gears is connected to a wire pay-off motor through a drive shaft, and multiple groups of mutually meshing wire transmission gear shafts are all extended into the inner side of the copper wire buffer space and are provided with two groups of wire pay-off belts.

[0016] Preferably, the copper wire cache space includes multiple groups of cache columns arranged in pairs vertically on the top surface of the bracket flat plate, cache baffles are respectively provided on the outer sides of the multiple groups of cache columns, and smooth steering rods are provided between the pairs of cache columns. The front side of the cache column is the wire conveying roller of the copper wire driving conveying component, and multiple layers of guide wheel mounting frames are provided on the rearmost cache column, and a cache guide wheel is installed on each layer of guide wheel mounting frame to assist in the feeding of flat copper wire; a group of wire pulling components are provided on the rear side of the cache guide wheel and are connected to a wire pulling motor.

[0017] Furthermore, the wire coil lifting electric cylinder, wire coil lifting motor, belt tensioning cylinder, wire coil driving motor, coil diameter measuring sensor, tensioning cylinder, laser rangefinder, wire pay-off motor, and wire pulling motor are electrically connected to a PLC control cabinet respectively, and the PLC control cabinet has filtering and PID control functions.

[0018] The control method for unwinding a wire coil using the flat wire motor unwinding device comprises the following steps:

[0019] Step 1: The wire coil to be unwound is placed on the unwinding shaft, and then the unwinding shaft is placed on two sets of auxiliary rollers through the guidance of two guide plates. Two wire coil lifting motors drive the lifting bracket through the wire coil lifting electric cylinder to drive the wire coil to rise synchronously until it contacts the rotating belt of the wire coil drive motor. The rotating belt is tightened by the belt tensioning cylinder, and the wire coil is driven by the wire coil drive motor to perform the unwinding operation; at the same time, the coil diameter measuring sensor starts to detect the coil diameter in real time;

[0020] Step 2: The flat copper wire is passed around the fixed guide wheel and the movable guide wheel, and the flat copper wire is tightened at the movable guide wheel by a tensioning cylinder while the position of the movable guide wheel is detected by a laser rangefinder;

[0021] Step 3: The PLC control cabinet matches the wire winding speed and the pay-off belt speed according to the wire winding diameter; and performs speed compensation according to the position of the movable guide wheel;

[0022] Step 4: The PLC control cabinet calculates the cumulative wire feeding length according to the wire pulling action of the wire pulling component and the position of the wire paying-off motor to calculate the cumulative wire feeding length of the wire paying-off belt;

[0023] Step 5: Filter the accumulated wire length signal to make it smooth;

[0024] Step 6: The PLC control cabinet calculates the difference between the filtered signal of the cumulative wire feeding length of the wire pulling component and the cumulative wire feeding length of the pay-off belt, and performs PID control; ensures that the wire feeding length of the pay-off belt matches the wire feeding length of the wire pulling component, and ensures that there is always a certain amount of copper wire in the cache area.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] The copper wire tension is adjusted in real time by tightening the movable guide wheel to avoid looseness or over-tightening. The pay-off belt isolates the wire coil from the wire pulling components, significantly reducing the tensile force on the copper wire (by more than 30%) and preventing wire damage. The coil diameter measurement sensor monitors the coil diameter in real time, and the PLC control cabinet dynamically adjusts the unwinding motor speed to ensure that the wire speed matches the pay-off belt speed and maintains constant tension.

[0027] The copper wire buffer space uses a multi-layer guide wheel structure to store redundant copper wire. Combined with the wire length PID closed-loop control of the pay-off belt and the wire pulling component, it eliminates speed fluctuations, achieves continuous unwinding, and adapts to the high cycle time of less than 1 second. The cumulative wire feeding length matching algorithm smoothly processes the signal, reducing the number of motor starts and stops (by more than 50%) and extending the life of the equipment.

[0028] The noise of the cumulative wire feeding length signal is eliminated through filtering, and the PID control corrects the deviation between the unwinding speed and the wire pulling speed in real time. The wire length error is controlled within ±0.1%, ensuring the consistency of flat wire forming.

[0029] The unwinding, tensioning, and buffering devices are independently adjustable, compatible with copper wire coils of different specifications (such as flat copper wire with a width of 2-8mm), and suitable for a variety of wire forming equipment;

[0030] In summary, the present invention solves the problems of poor stability, copper wire damage and beat bottleneck of traditional passive unwinding through the collaborative innovation of active unwinding and cache control, provides key technical support for the high-efficiency and high-quality production of flat wire motors, and has significant economic benefits and industry promotion value. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 Schematic diagram of the device of the present invention;

[0032] Figure 2 for Figure 1 Structural diagram;

[0033] Figure 3 It is a schematic diagram of the unwinding device;

[0034] Figure 4 This is a schematic diagram of the tensioning and monitoring device;

[0035] Figure 5 This is a schematic diagram of the copper wire cache mechanism;

[0036] Figure 6 It is a schematic diagram of the composition of the device of the present invention;

[0037] Figure 7 This is a control principle diagram of the unwinding device of the present invention;

[0038] Figure 8 This is a control principle diagram of the wire laying of the present invention;

[0039] Figure 9 This is the actual effect diagram of the matching between the cumulative wire feeding length of the pay-off belt and the cumulative wire feeding length of the wire pulling component;

[0040] Figure 10 This is a comparison diagram of the actual effect of the pay-off speed of the present invention;

[0041] Figure 11This is a diagram showing the actual effect of controlling the unwinding process of the present invention;

[0042] Figure: Unwinding device 1, unwinding base plate 11, unwinding base plate 111, anchor bolts 112, base inclined plate 113, unwinding bracket 12, bracket base plate 121, bracket vertical plate 122, inclined plate reinforcement rib 123, unwinding horizontal frame 13, horizontal frame flat plate 131, lifting motor through hole 132, tensioning cylinder mounting hole 133, drive motor mounting hole 134, unwinding mechanism 14, unwinding vertical plate Plate-141, unwinding guide rail-142, lifting motor bracket-143, wire coil lifting cylinder-144, lifting bracket-145, auxiliary roller-146, unwinding shaft-147, wire coil lifting motor-148, belt tensioning cylinder-149, tensioning mounting plate-150, wire coil drive motor-151, guide plate-152, tensioning and monitoring device-2, fixed guide wheel part-21, fixed guide wheel base plate-211, column Fixed seat 212, cylindrical column 213, locking slider 214, fixed guide wheel support plate 215, fixed guide wheel 216, tension monitoring unit 22, guide wheel base plate 221, bracket mounting seat 222, bracket mounting base plate 223, bearing seat 224, swing bracket 225, swing plate 226, tensioning cylinder 227, movable guide wheel 228, laser rangefinder 229, copper wire buffer Storage device-3, cache bracket-31, bracket frame-311, bracket plate-312, adjustment foot-313, fixed inclined foot-314, copper wire drive conveying component-32, copper wire drive frame-321, wire conveying gear-322, wire pay-off motor-323, copper wire cache space-33, cache column-331, cache baffle-332, steering rod-333, guide wheel mounting frame-334, cache guide wheel-335. DETAILED DESCRIPTION

[0043] In order to enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions in the embodiments of the present invention are clearly and completely described below in conjunction with the accompanying drawings and specific embodiments.

[0044] Please refer to Figure 1-11 , Figure 1 Schematic diagram of the device of the present invention; Figure 2 for Figure 1 Structural diagram; Figure 3 It is a schematic diagram of the unwinding device; Figure 4 This is a schematic diagram of the tensioning and monitoring device; Figure 5 This is a schematic diagram of the copper wire cache mechanism; Figure 6 It is a schematic diagram of the composition of the device of the present invention; Figure 7 This is a control principle diagram of the unwinding device of the present invention; Figure 8 This is a control principle diagram of the wire laying of the present invention; Figure 9This is the actual effect diagram of the matching between the cumulative wire feeding length of the pay-off belt and the cumulative wire feeding length of the wire pulling component; Figure 10 This is a comparison diagram of the actual effect of the pay-off speed of the present invention; Figure 11 This is a diagram showing the actual effect of controlling the unwinding process of the present invention.

[0045] The present invention provides a flat wire motor unwinding device, which is used to ensure that the wire coil always remains in a tensioned state during the unwinding process, reduce the tensile force on the copper wire during the wire pulling process, and at the same time ensure the speed continuity and responsiveness during the unwinding process, and reduce the speed fluctuation and start-stop frequency of the wire coil; it comprises an unwinding device 1, a tensioning and monitoring device 2, and a copper wire buffer device 3 which are arranged in sequence.

[0046] The unwinding device 1 includes a horizontally arranged unwinding base plate 11, and mirror-image unwinding brackets 12 are respectively arranged on the top surface of the unwinding base plate 11 near the middle of its left and right sides. The top ends of the two unwinding brackets 12 are jointly provided with a horizontal unwinding cross frame 13, and an unwinding mechanism 14 for unwinding is jointly provided through the unwinding brackets 12 and the unwinding cross frame 13.

[0047] The unwinding base plate 11 includes a rectangular unwinding base plate 111, and a through hole and an anchor bolt 112 are respectively provided at the four corners of the unwinding base plate 111 for installing and fixing the unwinding base plate 11; a base inclined plate 113 with a triangular cross-section is provided at the front side of the unwinding base plate 111 for assisting the loading of the coiled material.

[0048] The unwinding bracket 12 includes a bracket bottom plate 121 arranged on the top surface of the unwinding base plate 111, and a bracket vertical plate 122 is vertically arranged on the side close to each other on the top surface of the two bracket bottom plates 121. Two inclined plate reinforcement ribs 123 are respectively arranged between the outer side surface of the bracket vertical plate 122 and the top surface of the bracket bottom plate 121 to ensure the structural strength of the unwinding bracket 12.

[0049] The unwinding horizontal frame 13 includes a horizontal frame plate 131, and the horizontal frame plate 131 is respectively provided with a lifting motor through hole 132 near the support vertical plate 122 on both sides, two tensioning cylinder mounting holes 133 are provided between the two lifting motor through holes 132, and a driving motor mounting hole 134 is provided on the rear side between the two tensioning cylinder mounting holes 133.

[0050] The unwinding mechanism 14 includes an unwinding vertical plate 141 arranged on the inner side surface of the bracket vertical plate 122, and two unwinding guide rails 142 are vertically arranged on the inner side surface of the unwinding vertical plate 141. At the same time, a lifting motor bracket 143 is arranged above the unwinding guide rail 142 and a wire roll lifting electric cylinder 144 is arranged thereon. The two unwinding guide rails 142 on the same side are jointly provided with a lifting bracket 145 through a slider, and the lifting bracket 145 is connected to the wire roll lifting electric cylinder 144; two auxiliary rollers 146 are provided on the inner side of the lifting bracket 145, and a horizontal unwinding shaft 147 is jointly supported between the two groups of auxiliary rollers 146. The wire roll to be unwound is sleeved on the outer side of the unwinding shaft 147 for unwinding operation.

[0051] Two wire reel lifting electric cylinders 144 pass through the lifting motor through hole 132 and are connected to a wire reel lifting motor 148 at the top; a belt tensioning cylinder 149 is installed at each of the two tensioning cylinder mounting holes 133, and the piston shaft of the belt tensioning cylinder 149 is connected to a tensioning mounting plate 150. Tension pulleys are respectively provided on the outer sides of the two tensioning mounting plates 150 to assist in tightening the rotating belt; a wire reel driving motor 151 is provided at the drive motor mounting hole 134, and the wire reel driving motor 151 is connected to a pulley and a rotating belt for wire pay-off operation;

[0052] A guide plate 152 is provided on the lifting bracket 145 between the auxiliary roller 146 and the wire coil lifting cylinder 144 through the bracket to assist the wire coil in accurately positioning when loading.

[0053] In addition, a wire coil diameter measuring sensor is provided on the bottom surface of the horizontal frame plate 131 for detecting the wire coil diameter in real time.

[0054] The tensioning and monitoring device 2 is arranged on the top surface of the unwinding base plate 111 near the rear side, and includes a fixed guide wheel portion 21 arranged on the front side and a tensioning monitoring portion 22 arranged on the rear side.

[0055] The fixed guide wheel portion 21 includes a fixed guide wheel base plate 211 arranged on the top surface of the unwinding base plate 111, and a column fixing seat 212 is respectively provided on the top surface of the fixed guide wheel base plate 211 near both ends, and a cylindrical column 213 is vertically provided at the axis of the column fixing seat 212, and a locking slider 214 that can be lifted and lowered is provided on the cylindrical column 213, and a fixed guide wheel support plate 215 is respectively provided on the side where the two locking sliders 214 are close to each other, and a concave support groove is provided at the middle of the top of the two fixed guide wheel support plates 215 and a fixed guide wheel 216 is commonly provided.

[0056] The tension monitoring unit 22 includes a guide wheel base plate 221 arranged on the top surface of the unwinding base plate 111, and a column fixing seat 212 is provided on the top surface of the guide wheel base plate 221 near both ends. A cylindrical column 213 is vertically provided at the axis of the column fixing seat 212, and a bracket mounting seat 222 is provided at the top of the cylindrical column 213. A bracket mounting base plate 223 is horizontally provided on the top of the bracket mounting seat 222, and a bearing seat 224 is provided on the top surface of the bracket mounting base plate 223. The bearing seat 224 is provided with a swing bracket 225 through a bearing. The two swing brackets are jointly provided with a swing plate 226. Two tensioning cylinders 227 are provided on the top surface of the swing plate 226 through a bracket. The ends of the piston shafts of the two tensioning cylinders 227 are jointly provided with a movable guide wheel 228. A laser rangefinder 229 is provided on the two tensioning cylinders 227 on the swing plate 226 through a bracket.

[0057] The copper wire buffer device 3 includes a buffer bracket 31 . A copper wire driving and conveying component 32 is provided on the top surface of the buffer bracket 31 near the left front side, and a copper wire buffer space 33 is provided on the right side of the copper wire driving and conveying component 32 .

[0058] The cache bracket 31 includes a bracket frame 311 assembled from profiles, a bracket plate 312 is provided on the top surface of the bracket frame 311, a copper wire driving and conveying component 32 is provided on the top surface of the bracket plate 312 near the left front side, and a copper wire cache space 33 is provided on the right side of the copper wire driving and conveying component 32; a plurality of adjustment feet 313 are provided on the bottom surface of the bracket frame 311, and a fixed inclined foot 314 is provided on the side wall of the bracket frame 311 on the outside of the adjustment foot 313 to assist in the installation and fixation of the cache bracket.

[0059] The copper wire drive conveying component 32 includes a rectangular copper wire drive frame 321, and multiple groups of mutually meshing wire transmission gears 322 are arranged inside the copper wire drive frame 321, and one of the wire transmission gears 322 is connected to a wire pay-off motor 323 through a drive shaft. The multiple groups of mutually meshing wire transmission gears 322 shafts are all deep into the inner side of the copper wire buffer space 33 and are provided with two groups of wire pay-off belts. The copper wire is placed between the two groups of wire pay-off belts for wire pulling operations.

[0060] The copper wire cache space 33 includes a plurality of groups of cache columns 331 arranged in pairs vertically on the top surface of the support flat plate 312, and cache baffles 332 are respectively arranged on the outer sides of the plurality of groups of cache columns 331. At the same time, a smooth steering rod 333 is arranged between the pairs of cache columns 331. The front side of the cache column 331 is the wire conveying roller of the copper wire driving conveying component 32, and a plurality of layers of guide wheel mounting frames 334 are arranged on the rearmost cache column 331, and a cache guide wheel 335 is installed on each layer of guide wheel mounting frame 334 for assisting the feeding of flat copper wire; a group of wire pulling components are arranged on the rear side of the cache guide wheel 335 and are connected to a wire pulling motor.

[0061] In addition, the wire coil lifting electric cylinder 144, wire coil lifting motor 148, belt tensioning cylinder 149, wire coil driving motor 151, coil diameter measuring sensor, tensioning cylinder 227, laser rangefinder 229, wire pay-off motor 323, and wire pulling motor are respectively electrically connected to the PLC control cabinet. The PLC control cabinet has filtering and PID control functions, and matches the wire coil speed and the wire pay-off belt speed according to the wire coil diameter; the cumulative wire feeding length signal is processed by filtering to make the signal smooth; the PLC control cabinet calculates the difference between the filtered signal of the cumulative wire feeding length of the wire pulling component and the cumulative wire feeding length of the wire pay-off belt, and performs PID control; ensures that the wire feeding length of the wire pay-off belt matches the wire feeding length of the wire pulling component, and ensures that there is always a certain amount of copper wire in the cache area.

[0062] The control method for unwinding a wire coil using the flat wire motor unwinding device comprises the following steps:

[0063] Step 1: The wire coil to be unwound is placed on the unwinding shaft 147, and then the unwinding shaft 147 is placed on two sets of auxiliary rollers 146 through the guidance of two guide plates 152. Two wire coil lifting motors 148 drive the lifting bracket 145 through the wire coil lifting electric cylinder 144 to drive the wire coil to rise synchronously until it contacts the rotating belt of the wire coil drive motor 151. The belt tensioning cylinder 149 tightens the rotating belt, and the wire coil is driven by the wire coil drive motor 151 to perform the unwinding operation; at the same time, the coil diameter measuring sensor starts to detect the coil diameter in real time;

[0064] Step 2: The flat copper wire passes around the fixed guide wheel 216 and the movable guide wheel 228 , and the flat copper wire is tightened at the movable guide wheel 228 by the tensioning cylinder 227 while the position of the movable guide wheel 228 is detected by the laser rangefinder 229 ;

[0065] Step 3: The PLC control cabinet matches the wire winding speed and the pay-off belt speed according to the wire winding diameter; and performs speed compensation according to the position of the movable guide wheel 228;

[0066] Step 4: The PLC control cabinet calculates the cumulative wire feeding length according to the wire pulling action of the wire pulling component and the position of the wire paying-off motor 323 to calculate the cumulative wire feeding length of the wire paying-off belt;

[0067] Step 5: Filter the accumulated wire length signal to make it smooth;

[0068] Step 6: The PLC control cabinet calculates the difference between the filtered signal of the cumulative wire feeding length of the wire pulling component and the cumulative wire feeding length of the pay-off belt, and performs PID control; ensures that the wire feeding length of the pay-off belt matches the wire feeding length of the wire pulling component, and ensures that there is always a certain amount of copper wire in the cache area.

[0069] Although embodiments of the present invention have been shown and described, it is apparent that the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, it is understood by those skilled in the art that all other embodiments obtained by various changes, modifications, substitutions, and variations of these embodiments without departing from the principles and spirit of the present invention and without making any creative effort are within the scope of protection of the present invention.

Claims

1. A flat wire motor unwinding device, characterized by: The invention comprises an unwinding device (1), a tensioning and monitoring device (2), a copper wire buffer device (3) and a PLC control cabinet which are arranged in sequence, wherein the PLC control cabinet has filtering and PID control functions; the unwinding device (1) comprises a horizontally arranged unwinding base plate (11) and an unwinding bracket (12) is mirror-imaged on the top surface thereof near the middle of the left and right sides thereof, the top ends of the two unwinding brackets (12) are jointly provided with a horizontal unwinding horizontal frame (13), and an unwinding mechanism (14) is jointly provided through the unwinding bracket (12) and the unwinding horizontal frame (13); a coil diameter measuring sensor is arranged on the bottom surface of the unwinding horizontal frame (13); the unwinding mechanism (14) comprises two coil lifting electric cylinders (144), the coil lifting electric cylinders (144) are respectively provided with a coil diameter measuring sensor; ... 44) is connected to a lifting bracket (145), two auxiliary rollers (146) are provided on the inner side of the lifting bracket (145), and a horizontal unwinding shaft (147) is supported between the two sets of auxiliary rollers (146); two belt tensioning cylinders (149) are provided on the bottom surface of the unwinding horizontal frame (13), and the piston shafts of the belt tensioning cylinders (149) are connected to the tensioning mounting plates (150), and tensioning wheels are provided on the outer side surfaces of the two tensioning mounting plates (150) to assist in tightening the rotating belt; a wire coil driving motor (151) is provided on the bottom surface of the unwinding horizontal frame (13), and the wire coil driving motor (151) is connected to a pulley and a rotating belt; the tensioning and monitoring device (2) is provided on the bottom surface of the unwinding horizontal frame (13). The top surface of the plate (11) near the rear side includes a fixed guide wheel portion (21) arranged on the front side and a tension monitoring portion (22) arranged on the rear side; the tension monitoring portion (22) includes two bearing seats (224) arranged through a bracket, the bearing seat (224) is provided with a swing bracket (225) through a bearing, the two swing brackets are jointly provided with a swing plate (226), two tensioning cylinders (227) are arranged on the top surface of the swing plate (226) through a bracket, the ends of the piston shafts of the two tensioning cylinders (227) are jointly provided with a movable guide wheel (228), and a laser rangefinder (229) is provided on the swing plate (226) on the two tensioning cylinders (227) through a bracket; the copper wire buffer device (3) includes The invention relates to a buffer bracket (31) and a copper wire driving and conveying component (32) is arranged on the top surface thereof near the left front side, and a copper wire buffer space (33) is arranged on the right side of the copper wire driving and conveying component (32); the copper wire driving and conveying component (32) includes a rectangular copper wire driving frame (321), and the copper wire driving frame (321) is provided with a plurality of groups of mutually meshing wire transmission gears (322) inside, and one of the wire transmission gears (322) is connected to a wire pay-off motor (323) through a driving shaft, and the shafts of the plurality of groups of mutually meshing wire transmission gears (322) are all extended into the inner side of the copper wire buffer space (33) and are provided with two groups of wire pay-off belts; a group of wire pulling components is provided near the rear side of the copper wire buffer space (33) and is connected to the wire pulling motor.

2. The flat wire motor unwinding device according to claim 1, characterized in that: The unwinding base plate (11) comprises a rectangular unwinding base plate (111) and a through hole is provided at each of its four corners and anchor bolts (112); a base inclined plate (113) with a triangular cross section is provided at the front side of the unwinding base plate (111); the unwinding bracket (12) comprises a bracket base plate (121), and bracket upright plates (122) are vertically provided on the sides of the top surfaces of the two bracket base plates (121) close to each other, and a support is provided between the outer side surface of the bracket upright plate (122) and the top surface of the bracket base plate (121). Two inclined plate reinforcement ribs (123) are provided; the unwinding horizontal frame (13) includes a horizontally arranged horizontal frame plate (131); the horizontal frame plate (131) is provided with a lifting motor through hole (132) at a position close to the bracket vertical plates (122) on both sides, a tensioning cylinder mounting hole (133) is provided on the inner side of the two lifting motor through holes (132), and a driving motor mounting hole (134) is provided on the rear side between the two tensioning cylinder mounting holes (133); the coil diameter measuring sensor is provided on the bottom surface of the horizontal frame plate (131).

3. The flat wire motor unwinding device according to claim 2, characterized in that: The unwinding mechanism (14) includes an unwinding vertical plate (141) arranged on the inner side of the bracket vertical plate (122) and two unwinding guide rails (142) vertically arranged on the inner side thereof, a lifting motor bracket (143) is arranged above the unwinding guide rail (142) and the wire coil lifting electric cylinder (144) is arranged thereon, and the two unwinding guide rails (142) on the same side are jointly provided with the lifting bracket (145) through a slider; the two wire coil lifting electric cylinders (144) pass through the lifting motor through hole (132) and are connected to the wire coil lifting motor (148) at the top; one belt tensioning cylinder (149) is respectively installed at the two tensioning cylinder mounting holes (133); the wire coil driving motor (151) is arranged at the driving motor mounting hole (134); and a guide plate (152) is provided on the lifting bracket (145) between the auxiliary roller (146) and the wire coil lifting electric cylinder (144) through the bracket.

4. The flat wire motor unwinding device according to claim 3, characterized in that: The fixed guide wheel portion (21) includes a fixed guide wheel base plate (211) arranged on the top surface of the unwinding base plate (111), a column fixing seat (212) is respectively provided on the top surface of the fixed guide wheel base plate (211) near both ends, a cylindrical column (213) is vertically provided at the axis of the column fixing seat (212), a locking slider (214) that can be adjusted up and down is provided on the cylindrical column (213), a fixed guide wheel support plate (215) is respectively provided on the side where the two locking sliders (214) are close to each other, and a concave support groove is provided at the middle of the top of the two fixed guide wheel support plates (215) and a fixed guide wheel (216) is provided on both.

5. The flat wire motor unwinding device according to claim 4, characterized in that: The tension monitoring part (22) includes a guide wheel base plate (221) arranged on the top surface of the unwinding base plate (111), a column fixing seat (212) is respectively arranged on the top surface of the guide wheel base plate (221) near both ends, a cylindrical column (213) is vertically arranged at the axis of the column fixing seat (212), a bracket mounting seat (222) is arranged on the top of the cylindrical column (213), a bracket mounting base plate (223) is horizontally arranged at the top of the bracket mounting seat (222), and a bearing seat (224) is arranged on the top surface of the bracket mounting base plate (223).

6. The flat wire motor unwinding device according to claim 5, characterized in that: The cache bracket (31) includes a bracket frame (311) assembled from profiles, a bracket plate (312) is provided on the top surface of the bracket frame (311), a copper wire driving and conveying component (32) is provided on the top surface of the bracket plate (312) near the left front side, and a copper wire cache space (33) is provided on the right side of the copper wire driving and conveying component (32); a plurality of adjustment feet (313) are provided on the bottom surface of the bracket frame (311), and fixed inclined feet (314) are provided on the side walls of the bracket frame (311) on the outside of the adjustment feet (313).

7. The flat wire motor unwinding device according to claim 6, characterized in that: The copper wire buffer space (33) includes a plurality of groups of paired buffer columns (331) vertically arranged on the top surface of the support plate (312), and buffer baffles (332) are respectively arranged on the outer sides of the plurality of groups of buffer columns (331). At the same time, a smooth steering rod (333) is arranged between the paired buffer columns (331). The front side of the buffer columns (331) is a wire conveying roller of the copper wire driving conveying component (32), and a plurality of layers of guide wheel mounting frames (334) are arranged on the rearmost buffer columns (331). A buffer guide wheel (335) is installed on each layer of the guide wheel mounting frames (334) for assisting the feeding of the flat copper wire; the rear side of the buffer guide wheel (335) is provided with the wire pulling component and is connected to the wire pulling motor.

8. The flat wire motor unwinding device according to claim 7, characterized in that: The wire coil lifting electric cylinder (144), the wire coil lifting motor (148), the belt tensioning cylinder (149), the wire coil driving motor (151), the coil diameter measuring sensor, the tensioning cylinder (227), the laser rangefinder (229), the wire pay-off motor (323), and the wire pulling motor are electrically connected to the PLC control cabinet.

9. A method for controlling the unwinding of a flat wire coil using the flat wire motor unwinding device according to claim 8, comprising the following steps: Step 1: The wire coil to be unwound is placed on the unwinding shaft (147), and then the unwinding shaft (147) is placed on two sets of auxiliary rollers (146) through the guidance of two guide plates (152). Two wire coil lifting motors (148) drive the lifting bracket (145) through the wire coil lifting electric cylinder (144) to drive the wire coil to rise synchronously until it contacts the rotating belt of the wire coil driving motor (151). The rotating belt is tightened by the belt tightening cylinder (149), and the wire coil is driven by the wire coil driving motor (151) to perform the unwinding operation; at the same time, the coil diameter measuring sensor starts to detect the coil diameter in real time; Step 2: The flat copper wire is passed around the fixed guide wheel (216) and the movable guide wheel (228), and the flat copper wire is tightened at the movable guide wheel (228) by the tensioning cylinder (227) and the position of the movable guide wheel (228) is detected by the laser rangefinder (229); Step 3: The PLC control cabinet matches the wire winding speed and the wire pay-off belt speed according to the wire winding diameter; and performs speed compensation according to the position of the movable guide wheel (228); Step 4: The PLC control cabinet calculates the cumulative wire feeding length according to the wire pulling action of the wire pulling component and the position of the wire paying-off motor (323) to calculate the cumulative wire feeding length of the wire paying-off belt; Step 5: Filter the accumulated wire length signal to make it smooth; Step 6: The PLC control cabinet calculates the difference between the filtered signal of the cumulative wire feeding length of the wire pulling component and the cumulative wire feeding length of the pay-off belt, and performs PID control; ensures that the wire feeding length of the pay-off belt matches the wire feeding length of the wire pulling component, and ensures that there is always a certain amount of copper wire in the cache area.

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