SMD (Surface Mount Device) annular inductor and processing technology thereof
By combining the flip-clamping assembly and the position adjustment assembly, the problem of poor adaptability of traditional surface mount toroidal inductor tin plating process is solved, realizing automated and efficient production of various tin plating methods.
Patent Information
- Application Number
- CN202511293672.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-11
- Publication Date
- 2025-10-31
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
In the existing technology, the traditional tin plating process for surface mount toroidal inductors is only applicable to toroidal cores of specific specifications. The clamping range of the fixture is limited, making it difficult to meet the requirements of various tin plating processes, especially for large toroidal cores, where its universality is poor.
Employing a flip-clamping assembly and a position adjustment assembly, the device clamps toroidal cores of different sizes using the flip-clamping assembly and achieves automated linkage with the position adjustment assembly. This enables various wire-end tinning methods, such as tilted tinning and vertical tinning, to meet different process requirements.
It improved process adaptability, enhanced tin plating quality, and enabled automation and continuity of the production process, thereby increasing production efficiency and capacity.
Smart Images
Figure CN120878423A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of inductor manufacturing technology, and in particular to a surface mount toroidal inductor and its processing technology. Background Technology
[0002] A surface mount toroidal inductor is a surface mount inductor with a toroidal magnetic core design. Due to its compact structure and stable performance, it is widely used in modern electronic devices. Its core consists of a toroidal magnetic core and a copper coil wound on it. The closed toroidal structure of the magnetic core can effectively reduce magnetic leakage and electromagnetic interference, while providing high inductance and current carrying capacity.
[0003] The production process of surface-mount toroidal inductors mainly includes core preparation, winding, tin plating and soldering, encapsulation and curing, testing and sorting, and packaging and shipping. First, a suitable core material is selected based on the inductor performance requirements. The core is then pressed into a toroid using a mold and sintered at high temperature to cure it. Next, a toroidal winding machine is used to control the winding tension and evenly wind copper wire onto the toroidal ring. For surface-mount models, the wire ends are tin-plated or nickel-plated to enhance solderability before being soldered to the core electrodes. Then, epoxy resin or silicone is applied for protection, and the inductor is cured at high temperature. After completion, the inductor undergoes rigorous electrical testing and visual inspection to ensure it meets specifications before being graded according to performance.
[0004] In the production process of surface mount toroidal inductors, the ends of the copper wires wound on the toroidal core need to be tin-plated. In the traditional process, the toroidal core is usually held directly by a moving fixture, and the four copper wire ends are immersed in molten tin to tin-plat the four leads of the toroidal core at the same time. However, the traditional process is only applicable to toroidal cores of specific specifications, and the tin-plating method is relatively simple and cannot meet the requirements of various tin-plating processes. When dealing with larger toroidal cores, the clamping range of the fixture is limited and the versatility is poor. Therefore, in order to solve the above problems, a surface mount toroidal inductor and its processing technology are proposed. Summary of the Invention
[0005] The purpose of this invention is to address the shortcomings of existing technologies by proposing a surface-mount toroidal inductor and its processing technology.
[0006] To achieve the above objectives, the present invention adopts the following technical solution: A surface mount toroidal inductor includes a housing, an inner toroidal magnetic core body is installed inside the housing, an enameled wire is wound around the inner toroidal magnetic core body, a plurality of guide grooves are provided through the bottom of the housing, and a plurality of pin brackets are provided on the outside of the housing, with an enameled wire wound around the pin brackets.
[0007] A fabrication process for a surface-mount toroidal inductor specifically includes the following steps: S1. Winding: Use a toroidal winding machine to evenly wind the enameled wire onto the toroidal magnetic core; S2, Tin plating: Tin plating is performed on the wire ends using tin plating equipment. The clamping and flipping assembly installed on the control cabinet clamps the ring core with enameled wire wound on it, and tin plating is performed on multiple wire ends on the ring core. The tin-plated ring core body is installed inside the housing, and the two ends of the winding are welded to the pin hanging corners on the housing. S3. Soldering: Fix the solder pad inside the housing, and let the enameled wire pass through the guide groove and hang on the pin bracket. The main wire body is not exposed, and the exposed point is on the top surface. There are no other components on the top surface of the circuit board, only on the side, so there is no risk of arcing. When soldering, solder 2 pins at a time to prevent the molten solder from flowing into the housing from the guide groove and damaging the magnetic core enameled wire. There is a 1mm distance between the outer shell and the bottom surface at the pin bracket position, so that the soldering can be fully covered and prevent cold solder joints.
[0008] A processing technology for a surface mount toroidal inductor, wherein the tin plating equipment includes a control cabinet, the top of the control cabinet is provided with a position adjustment component, the position adjustment component includes a vertical lifting plate, the vertical lifting plate moves up and down, and a horizontally moving plate is slidably provided on the vertical lifting plate; The horizontal moving plate is provided with a flip clamping assembly, which includes a rotating seat with an adjustable angle. A limit plate is installed on the rotating seat, and a drive plate is rotatably connected to the limit plate. Multiple clamping cylinders are rotatably arranged at equal intervals between the drive plate and the limit plate. The clamping cylinders are used to clamp and flip the annular magnetic core.
[0009] The above technical solution further includes: The control cabinet is equipped with a conveyor belt body. A mounting plate is fixedly connected to the side of the conveyor belt body. Cylinder clamps are symmetrically mounted on the mounting plate. A conveyor belt motor is mounted on the side of the conveyor belt body away from the mounting plate. The output end of the conveyor belt motor is connected to the conveyor belt body through a transmission. The control cabinet is equipped with a tin plating tank and a cooling tank. A support frame is also installed on the top of the conveyor belt body. Telescopic cylinders are symmetrically installed on the side of the support frame near the tin plating tank. The telescopic ends of the two telescopic cylinders are equipped with scrapers.
[0010] The position adjustment assembly also includes vertical guide rails symmetrically and fixedly connected to the top of the control cabinet. A vertical threaded rod is rotatably connected to the inner side of the vertical guide rail. The vertical threaded rod is rotatably connected to the conveyor belt body. A first transmission sprocket is fixedly connected to one end of the vertical threaded rod extending to the outer side of the conveyor belt body. A first transmission chain is sleeved and connected between the two first transmission sprockets. One of the vertical threaded rods is fixedly connected to the output end of a vertical drive motor installed inside the conveyor belt body. The vertical lifting plate is threadedly connected to the vertical threaded rod and slides relative to the vertical guide rail. Slide rods that slide relative to the vertical lifting plate are symmetrically and fixedly connected to the control cabinet.
[0011] The bottom of the vertical lifting plate is symmetrically equipped with horizontal guide rails. The inner side of the horizontal guide rails is rotatably connected with horizontal threaded rods. Each of the two horizontal threaded rods is threadedly connected with a threaded slider that slides relative to the horizontal guide rail. The two threaded sliders are fixedly connected to the horizontal moving plate. A horizontal drive motor is installed on each of the two horizontal guide rails on the side that is far apart from each other. A second transmission sprocket is installed on the output end of the horizontal drive motor and the end of the horizontal threaded rod that extends to the outside of the horizontal guide rail and is close to the horizontal drive motor. A second transmission chain is sleeved and connected between the two second transmission sprockets.
[0012] The flipping clamping assembly also includes a flipping bracket fixedly connected to the bottom of the horizontal moving plate. A reversing rod is rotatably connected to the inner side of the flipping bracket. The reversing rod is fixedly connected to the rotating seat. A reversing motor is installed on the side of the flipping bracket. A driving bevel gear is fixedly connected to the output end of the reversing motor. A driven bevel gear is installed at the end of the reversing rod near the reversing motor. The driven bevel gear and the driving bevel gear mesh with each other.
[0013] A fixed cylinder is fixedly connected to the side of the rotating seat, and a support plate is fixedly connected to the inner side of the fixed cylinder. A flip motor is installed inside the fixed cylinder. A flip driven gear is rotatably connected between the output end of the flip motor and the support plate. Multiple transmission shafts are rotatably connected to the support plate. A flip master gear is installed on the transmission shaft. The flip master gears are evenly distributed around the outside of the flip driven gears. The flip driven gears mesh with the multiple flip master gears.
[0014] Each of the multiple drive shafts is fixedly connected to a universal joint at one end away from the rotating gear, and a rotating rod is fixedly connected to the end of each universal joint away from the drive shaft. The rotating rod is fixedly connected to the clamping cylinder.
[0015] The drive disk has multiple drive slots circumferentially through it, and the limiting disk has multiple limiting slots circumferentially through it. The rotating rod is mounted with bearings on its outer surface at the drive slots and limiting slots. The bearings slide relative to the drive slots and limiting slots. A gear ring is fixedly mounted on the outer side of the drive disk. A spacing adjustment motor is fixedly mounted on the outer side of the fixed cylinder. An adjustment gear that meshes with the gear ring is fixedly mounted on the output end of the spacing adjustment motor.
[0016] The present invention has the following beneficial effects: 1. In this invention, the flip-clamping assembly can clamp ring core bodies of different sizes. Since the angle of the rotating seat is adjustable, various wire end tinning methods such as tilting tinning and vertical tinning can be realized, thereby improving process adaptability and improving the tinning quality of different processes.
[0017] 2. In this invention, the position adjustment component and the flipping clamping component achieve automated linkage control. By pre-programming and setting processing parameters and process flow, the equipment can automatically complete the picking and placing, position adjustment, flipping and various processing steps of the toroidal magnetic core according to the set program, realizing the automation and continuity of the production process, and greatly improving production efficiency and capacity. Attached Figure Description
[0018] Figure 1 This is a top view schematic diagram of the overall structure of a first product of a surface-mount toroidal inductor according to the present invention; Figure 2 This is a bottom view schematic diagram of the overall structure of the first product of the surface mount toroidal inductor according to the present invention; Figure 3 This is a top view schematic diagram of the overall structure of a second product of a surface-mount toroidal inductor according to the present invention; Figure 4 This is a top view schematic diagram of the overall structure of a second product of a surface-mount toroidal inductor according to the present invention; Figure 5 This is a schematic diagram of the overall structure of the tin plating equipment in this invention; Figure 6 This is a schematic diagram of the conveyor belt body, tin plating tank, and cooling tank in this invention; Figure 7 This is a schematic diagram of the position adjustment component structure in this invention; Figure 8 This is a partial structural diagram of the position adjustment component in this invention; Figure 9 This is a schematic diagram of the horizontal guide rail and horizontal moving plate structure in this invention; Figure 10 This is a schematic diagram of the internal structure of the fixed cylinder in this invention; Figure 11This is a schematic diagram of the first side view of the flip-grip assembly in this invention; Figure 12 This is a schematic diagram of the second side view of the flip-grip assembly in this invention; Figure 13 for Figure 8 Enlarged schematic diagram of the structure at point A in the middle; Figure 14 for Figure 12 Enlarged schematic diagram of the structure at point B; Figure 15 This is a schematic diagram showing the positional relationship between the main wire ends of two types of toroidal magnetic cores.
[0019] In the diagram: 1. Control cabinet; 2. Conveyor belt body; 3. Tin plating tank; 4. Cooling tank; 5. Vertical guide rail; 6. Fixed cylinder; 7. First outer shell; 70. First ejector pin bracket; 71. First annular magnetic core body; 8. Second outer shell; 80. Second annular magnetic core body; 81. Second ejector pin bracket; 82. Gasket; 20. Mounting plate; 21. Cylinder clamp; 22. Conveyor belt motor; 30. Support frame; 31. Telescopic cylinder; 32. Scraper; 50. Vertical threaded rod; 51. First transmission chain; 52. First transmission sprocket; 53. Vertical lifting plate; 54. Slide rod; 55. Horizontal guide rail; 56. Horizontal threaded rod; 57. Horizontal moving plate; 58. Horizontal... 59. Drive motor; 510. Second transmission sprocket; 511. Second transmission chain; 512. Vertical drive motor; 513. Threaded slider; 60. Tilting bracket; 61. Rotating seat; 62. Directional rod; 63. Universal joint; 64. Spacing adjustment motor; 65. Adjusting gear; 66. Gear ring; 67. Clamping cylinder; 670. Rotating rod; 68. Drive disc; 680. Drive groove; 69. Limiting disc; 690. Limiting groove; 610. Support disc; 611. Tilting motor; 612. Bearing; 613. Directional motor; 614. Driving bevel gear; 615. Driven bevel gear; 616. Tilting main gear; 617. Tilting driven gear; 618. Drive shaft. Detailed Implementation
[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0021] like Figures 1-14As shown, the present invention proposes a surface mount toroidal inductor and its processing technology. The tin plating equipment includes a housing, a toroidal magnetic core body is installed inside the housing, an enameled wire is wound on the toroidal magnetic core body, multiple guide grooves are opened through the bottom of the housing, and multiple ejector pins are provided on the outside of the housing, with an enameled wire wound on the ejector pins. Furthermore, the two types of surface mount toroidal inductors have similar structures. The first toroidal magnetic core body 71 is installed inside the first housing 7. Enamelled wire is wound on the first toroidal magnetic core body 71. The enamelled wire passes through the four wire ends on the outside of the first housing 7 and is connected to the four first pin brackets 70 of the first housing 7 respectively. Specifically, the enamelled wire is wound twice on the first pin bracket 70, and the wire end is stuck inside the groove of the first pin bracket 70. Furthermore, a second annular magnetic core body 80 is installed on the inner side of the second outer shell 8. Gaskets 82 are welded to the four corners of the top of the second outer shell 8. Enamelled wire is wound around the second pin bracket 81, passing through the four ends of the wire on the outer side of the second outer shell 8 and connecting to the four second pin brackets 81 of the second outer shell 8 respectively. Specifically, the enamelled wire is wound once around the second pin bracket 81. like Figure 3-4 As shown, there is a guide groove on the upper part of the shell. The enameled wire passes through the guide groove and hangs on the ejector pin. The main wire body is not exposed to prevent arcing. The solder pad is inside the shell. When soldering this process, two ejector pins are soldered at a time to prevent the molten solder from flowing into the shell from the guide groove and damaging the enameled wire of the magnetic core. The pads are 1mm away from the bottom surface at the pin mounting position. This allows for full-coverage tinning without affecting the soldering effect or causing cold solder joints. Currently, most products on the market are soldered close to the bottom surface, which prevents the enameled wire wrapped around the pin from being tinned, resulting in poor soldering performance.
[0022] A fabrication process for a surface-mount toroidal inductor specifically includes the following steps: S1. Winding: Use a toroidal winding machine to evenly wind the enameled wire onto the toroidal magnetic core; S2, Tin plating: Tin plating is performed on the wire ends using tin plating equipment. The clamping and flipping assembly installed on control cabinet 1 clamps the ring magnetic core with enameled wire wound on it, and tin plating is performed on multiple wire ends on the ring magnetic core. The tin-plated ring magnetic core body is installed inside the outer shell, and the two ends of the winding are welded to the pin hanging corners on the outer shell. S3. Soldering: Fix the solder pad inside the housing, and let the enameled wire pass through the guide groove and hang on the pin bracket. The main wire body is not exposed, and the exposed point is on the top surface. There are no other components on the top surface of the circuit board, only on the side, so there is no risk of arcing. When soldering, solder 2 pins at a time to prevent the molten solder from flowing into the housing from the guide groove and damaging the magnetic core enameled wire. There is a 1mm distance between the outer shell and the bottom surface at the pin bracket position, so that the soldering can be fully covered and prevent cold solder joints.
[0023] like Figure 5 As shown, the tin plating equipment includes a control cabinet 1. A position adjustment component is provided on the top of the control cabinet 1. The position adjustment component includes a vertical lifting plate 53, which moves up and down. A horizontal moving plate 57 that moves horizontally is slidably provided on the vertical lifting plate 53. A flipping clamping assembly is provided on the horizontal moving plate 57. The flipping clamping assembly includes a rotating seat 61 with an adjustable angle. A limit plate 69 is installed on the rotating seat 61. A drive plate 68 is rotatably connected to the limit plate 69. Multiple clamping cylinders 67 are rotatably arranged at equal intervals between the drive plate 68 and the limit plate 69. The clamping cylinders 67 are used to clamp the annular magnetic core and flip it. Furthermore, the control cabinet 1, as the control core of the entire system, has a position adjustment component and a flip clamping component on its top that work together under PLC control to achieve precise operation of the toroidal magnetic core. The position adjustment component includes a vertical lifting plate 53 that moves up and down. Under the control command of the control cabinet 1, the vertical lifting plate 53 can move up and down in the vertical direction to adjust the position of the flip clamping component in height. Furthermore, by controlling the horizontal moving plate 57 to achieve horizontal movement, the flip clamping assembly can be positioned in the horizontal dimension of three-dimensional space. Furthermore, a flip-grip assembly is provided on the horizontal moving plate 57. The rotating seat 61 of this assembly has an adjustable angle. With the command sent by the control cabinet 1, the rotating seat 61 can rotate according to the preset angle parameters to adjust the tilt angle of the flip-grip assembly clamping the ring magnetic core body to adapt to the tin plating requirements of different processes.
[0024] like Figure 6 As shown, a conveyor belt body 2 is installed on the control cabinet 1. A mounting plate 20 is fixedly connected to the side of the conveyor belt body 2. Cylinder clamps 21 are symmetrically installed on the mounting plate 20. A conveyor belt motor 22 is installed on the side of the conveyor belt body 2 away from the mounting plate 20. The output end of the conveyor belt motor 22 is connected to the conveyor belt body 2 for transmission. The control cabinet 1 is equipped with a tin plating tank 3 and a cooling tank 4. The top of the conveyor belt body 2 is also equipped with a support frame 30. The support frame 30 is symmetrically equipped with telescopic cylinders 31 on the side near the tin plating tank 3. The telescopic ends of the two telescopic cylinders 31 are equipped with scrapers 32. Furthermore, the operator first places the toroidal magnetic core body on the cylinder clamp 21, and then drives the flip clamping assembly to move towards the cylinder clamp 21 through the position adjustment component. The flip clamping assembly clamps the toroidal magnetic core body from the inner ring. The four wire ends of the toroidal magnetic core body can extend horizontally outward, or the four wire ends can be approximately perpendicular to the ring surface of the toroidal magnetic core body (e.g., Figure 15 (as shown) Furthermore, at this time, the position adjustment component drives the annular magnetic core body to move into the tin plating tank 3. At this time, the telescopic ends of the two telescopic cylinders 31 drive the scraper 32 to move back and forth on one side to scrape off impurities on the surface of the tin liquid in the tin plating tank 3. The flipping clamping component drives the wire end of the annular magnetic core body to contact the tin liquid in the tin plating tank 3 to complete the tin plating. After each tin plating is completed, the two wire ends of the annular magnetic core body that have been tin-plated need to be moved into the cooling tank 4 for cooling. Finally, the annular magnetic core body is moved onto the conveyor belt body 2 and moved out of the working area under the drive of the conveyor belt motor 22.
[0025] like Figures 7-9 As shown, the position adjustment assembly also includes a vertical guide rail 5 symmetrically and fixedly connected to the top of the control cabinet 1. A vertical threaded rod 50 is rotatably connected to the inner side of the vertical guide rail 5. The vertical threaded rod 50 is rotatably connected to the conveyor belt body 2. A first transmission sprocket 52 is fixedly connected to one end of the vertical threaded rod 50 extending to the outer side of the conveyor belt body 2. A first transmission chain 51 is sleeved and connected between the two first transmission sprockets 52. One of the vertical threaded rods 50 is fixedly connected to the output end of the vertical drive motor 511 installed inside the conveyor belt body 2. The vertical lifting plate 53 is threadedly connected to the vertical threaded rod 50 and slides relative to the vertical guide rail 5. A slide rod 54 that slides relative to the vertical lifting plate 53 is symmetrically and fixedly connected to the control cabinet 1. A horizontal guide rail 55 is symmetrically installed at the bottom of the vertical lifting plate 53. A horizontal threaded rod 56 is rotatably connected to the inner side of the horizontal guide rail 55. A threaded slider 512 that slides relative to the horizontal guide rail 55 is threadedly connected to each of the two horizontal threaded rods 56. The two threaded sliders 512 are fixedly connected to the horizontal moving plate 57. A horizontal drive motor 58 is installed on the side of each of the two horizontal guide rails 55 that are far apart from each other. A second transmission sprocket 59 is installed on the output end of the horizontal drive motor 58 and the end of the horizontal threaded rod 56 that extends to the outside of the horizontal guide rail 55 and is close to the horizontal drive motor 58. A second transmission chain 510 is sleeved and connected between the two second transmission sprockets 59. Furthermore, in the position adjustment component, the vertical position of the flip clamping component needs to be adjusted first. At this time, the vertical drive motor 511 starts, and its output end drives the vertical threaded rod 50 connected to it to rotate. Through the transmission action of the first transmission chain 51 and the first transmission sprocket 52, the other vertical threaded rod 50 also rotates synchronously. Under the rotation action of the vertical threaded rod 50, due to the principle of thread transmission, the vertical lifting plate 53 will move up and down along the vertical guide rail 5. In addition, the slide rod 54 symmetrically fixed on the control cabinet 1 slides relative to the vertical lifting plate 53, which further enhances the stability of the movement of the vertical lifting plate 53 and prevents it from deviating or shaking during the lifting process.
[0026] Furthermore, after the vertical position adjustment is completed, the horizontal position of the flip-grip assembly is adjusted. When the horizontal drive motor 58 is started, the horizontal threaded rod 56 is driven to rotate through the transmission of the second transmission sprocket 59 and the second transmission chain 510. Since the threaded slider 512 is threadedly connected to the horizontal threaded rod 56 and slides relative to the horizontal guide rail 55, the threaded slider 512 will move horizontally along the horizontal guide rail 55 under the rotation of the horizontal threaded rod 56, thereby driving the horizontal moving plate 57 to achieve horizontal position adjustment. Through precise position adjustment in both the vertical and horizontal directions, the position adjustment assembly can accurately move the flip-grip assembly to the required position to meet the processing requirements of different positions and angles of the toroidal core during the processing of the surface mount toroidal inductor.
[0027] like Figures 10-12 As shown, the flipping clamping assembly also includes a flipping bracket 60 fixedly connected to the bottom of the horizontal moving plate 57. A reversing rod 62 is rotatably connected to the inner side of the flipping bracket 60. The reversing rod 62 is fixedly connected to the rotating seat 61. A reversing motor 613 is installed on the side of the flipping bracket 60. A driving bevel gear 614 is fixedly connected to the output end of the reversing motor 613. A driven bevel gear 615 is installed at the end of the reversing rod 62 near the reversing motor 613. The driven bevel gear 615 and the driving bevel gear 614 mesh with each other.
[0028] A fixed cylinder 6 is fixedly connected to the side of the rotating seat 61. A support plate 610 is fixedly connected to the inside of the fixed cylinder 6. A flip motor 611 is installed inside the fixed cylinder 6. A flip driven gear 617 is rotatably connected between the output end of the flip motor 611 and the support plate 610. Multiple transmission shafts 618 are rotatably connected to the support plate 610. A flip main gear 616 is installed on the transmission shaft 618. The flip main gears 616 are evenly distributed around the outside of the flip driven gears 617. The flip driven gears 617 and the multiple flip main gears 616 mesh with each other. Multiple drive shafts 618 are fixedly connected to one end of the rotating gear 617 away from the drive shaft 618, and a rotating rod 670 is fixedly connected to the end of the universal joint 63 away from the drive shaft 618. The rotating rod 670 is fixedly connected to the clamping cylinder 67. Multiple drive slots 680 are circumferentially opened on the drive disk 68, and multiple limit slots 690 are circumferentially opened on the limit disk 69. A bearing 612 is installed on the outer surface of the rotating rod 670 at the drive slots 680 and the limit slots 690. The bearing 612 slides relative to the drive slots 680 and the limit slots 690. A gear ring 66 is fixedly installed on the outer side of the drive disk 68, and a pitch adjustment motor 64 is fixedly installed on the outer side of the fixed cylinder 6. An adjustment gear 65 that meshes with the gear ring 66 is fixedly installed at the output end of the pitch adjustment motor 64. Furthermore, before tinning the ends of the toroidal magnetic core body, the vertical and horizontal movement of the horizontal moving plate 57 in the position adjustment mechanism is used to insert the clamping cylinder 67 into the center inner ring of the toroidal magnetic core body. Then, the control pitch adjustment motor 64 is started, and its output end drives the adjustment gear 65 to rotate. Since the adjustment gear 65 meshes with the gear ring 66 fixedly installed on the outside of the drive disk 68, the gear ring 66 will drive the drive disk 68 to rotate.
[0029] Furthermore, the multiple drive grooves 680 circumferentially formed on the drive disc 68 and the multiple limit grooves 690 circumferentially formed on the limit disc 69 provide a track for the movement of the rotating rod 670. The bearings 612 installed on the outer surfaces of the rotating rod 670 at the drive grooves 680 and the limit grooves 690 allow the rotating rod 670 to slide relative to each other within the drive grooves 680 and the limit grooves 690, reducing friction during movement and ensuring smooth movement. Furthermore, when it is necessary to adjust the spacing between the clamping cylinders 67 to accommodate toroidal magnetic cores of different sizes, the rotation of the drive disk 68, through the cooperation of the drive groove 680 and the bearing 612, and the limiting effect of the upper limit groove 690 of the limiting disk 69, causes the rotating rod 670 to drive the clamping cylinders 67 to move along a specific direction, thereby achieving precise adjustment of the spacing between the clamping cylinders 67, ensuring that toroidal magnetic core bodies of different specifications can be firmly and stably clamped, providing a reliable guarantee for subsequent processing operations.
[0030] Furthermore, during the tin plating process at the wire end of the toroidal magnetic core body, the flipping clamping assembly that has already clamped the toroidal magnetic core body is first moved into the tin plating tank 3 by the position adjustment assembly. According to the actual production process requirements, there are two tin plating methods. The first method is the tilted tin plating method. When it is necessary to adjust the angle of the rotating seat 61, the driving bevel gear 614 installed at its output end is driven to rotate by controlling the reversing motor 613. Because the driven bevel gear 615 meshes with the driving bevel gear 614, the driven bevel gear 615 will rotate accordingly, thereby driving the reversing rod 62 to rotate. The reversing rod 62 is fixedly connected to the rotating seat 61, and finally the precise adjustment of the angle of the rotating seat 61 is achieved. When the tilting tin plating method is applied to a toroidal magnetic core body (where the four wire ends of the toroidal magnetic core body extend horizontally outward), each time two wire ends are tinned, the toroidal magnetic core body needs to be lifted off the surface of the molten tin and rotated 180° to tin the other two wire ends. At this time, the flipping motor 611 is started by controlling the flipping motor 611 to start, and its output end drives the flipping driven gear 617 to rotate. The multiple drive shafts 618 rotatably connected to the support plate 610 are equipped with flipping main gears 616, and the flipping main gears 616 are evenly distributed around the outside of the flipping driven gear 617. Since the flipping driven gear 617 meshes with the multiple flipping main gears 616, the rotation of the flipping driven gear 617 will drive the multiple flipping main gears 616 to rotate synchronously, thereby causing the multiple drive shafts 618 to rotate together. Furthermore, a universal joint 63 is fixedly connected to one end of the drive shaft 618 away from the flipping gear 617. The universal joint 63 has good steering flexibility and can adapt to the transmission requirements of different angles. The rotating rod 670 fixedly connected to the end of the universal joint 63 away from the drive shaft 618 is fixedly connected to the clamping cylinder 67. In this way, the rotation of the drive shaft 618 is transmitted to the rotating rod 670 through the universal joint 63, which in turn drives the clamping cylinder 67 to rotate, thereby realizing the flipping action of the annular magnetic core. In addition, it is worth noting that since the universal joint 63 adopts a double decimal structure, it has good extensibility. Therefore, during the movement of the clamping cylinder 67, the rotation of the clamping cylinder 67 itself will not be affected due to the characteristics of the universal joint 63 itself. Furthermore, when tilted tin plating can be applied to a type of annular magnetic core (where the four wire ends are approximately perpendicular to the annular surface of the annular magnetic core body), the working principle is similar to that described above. The reversing motor 613 can be used to rotate the rotating seat 61 to a certain tilt angle, inserting the two wire ends of the annular magnetic core body into the tin plating tank 3. After the two wire ends of the annular magnetic core body have been tin-plated, the annular magnetic core body is lifted away from the surface of the tin liquid. At this time, the scraper 32 needs to scrape off the impurities on the surface of the tin plating tank 3. At this time, the reversing motor 613 needs to be started to rotate the rotating seat 61 to a direction that is symmetrical to the previous one, and the annular magnetic core body is inserted into the tin liquid again to tin-plat the other two wire ends. The annular magnetic core body is flipped without using the clamping cylinder 67 to rotate. Furthermore, after tinning the two ends of the toroidal core body, the toroidal core body is lifted, and the clamping cylinder 67 is rotated by the set flipping motor 611 to flip the toroidal core body and insert the other two ends of the toroidal core body into the molten tin. Furthermore, when vertical tin plating is applied to the above two types of toroidal magnetic core bodies, for the first type (the four wire ends of the toroidal magnetic core body extend horizontally outward), the rotating seat 61 is adjusted to an angle perpendicular to the surface of the molten tin, and the four wire ends are tinned twice by flipping the toroidal magnetic core body. Furthermore, the second method (with the four wire ends approximately perpendicular to the ring surface of the toroidal core body) involves directly inserting the four wire ends of the toroidal core body into the molten tin to complete a one-time tin plating.
[0031] In this embodiment, the equipment can flexibly select tilted tin plating or vertical tin plating method according to the different shapes of the toroidal magnetic core wire ends. For toroidal magnetic cores with different wire end shapes, efficient and precise tin plating can be achieved by adjusting the angle of the rotating seat 61 and flipping the toroidal magnetic core. In addition, the scraper 32 can remove impurities on the surface of the tin liquid in time to ensure the tin plating quality. After tin plating is completed, the toroidal magnetic core is moved to the cooling tank 4 for cooling. Finally, the conveyor belt body 2 moves out of the working area. The whole processing process is efficient, orderly and quality controllable.
[0032] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A surface-mount toroidal inductor, comprising a housing, characterized in that, The outer casing contains a ring-shaped magnetic core body with enameled wire wound around it. Multiple guide grooves are provided through the bottom of the outer casing, and multiple pin hooks are provided on the outside of the outer casing with enameled wire wound around them.
2. A fabrication process for a surface-mount toroidal inductor, characterized in that, Specifically, the following steps are included: S1. Winding: Use a toroidal winding machine to evenly wind the enameled wire onto the toroidal magnetic core; S2, Tin plating: Tin plating the wire ends by tin plating equipment, clamping and flipping components installed on the control cabinet (1) clamp the ring magnetic core with enameled wire, tin plating multiple wire ends on the ring magnetic core, installing the tin-plated ring magnetic core body inside the shell, and welding the two ends of the winding wire to the pin hanging corner on the shell. S3. Soldering: Fix the solder pad inside the housing, and let the enameled wire pass through the guide groove and hang on the pin bracket. The main wire body is not exposed, and the exposed point is on the top surface. There are no other components on the top surface of the circuit board, only on the side, so there is no risk of arcing. When soldering, solder 2 pins at a time to prevent the molten solder from flowing into the housing from the guide groove and damaging the magnetic core enameled wire. There is a 1mm distance between the outer shell and the bottom surface at the pin bracket position, so that the soldering can be fully covered and prevent cold solder joints.
3. A processing technology for a surface-mount toroidal inductor, wherein the tin plating equipment includes a control cabinet (1), characterized in that, The top of the control cabinet (1) is provided with a position adjustment component, which includes a vertical lifting plate (53), the vertical lifting plate (53) moves up and down, and a horizontal moving plate (57) is slidably provided on the vertical lifting plate (53). The horizontal moving plate (57) is provided with a flip clamping assembly, which includes a rotating seat (61) with an adjustable angle. A limiting disk (69) is installed on the rotating seat (61), and a driving disk (68) is rotatably connected to the limiting disk (69). Multiple clamping cylinders (67) are rotatably arranged between the driving disk (68) and the limiting disk (69) at equal distances. The clamping cylinders (67) are used to clamp the annular magnetic core and flip it.
4. The processing technology of a surface-mount toroidal inductor according to claim 3, characterized in that, The control cabinet (1) is equipped with a conveyor belt body (2), and a mounting plate (20) is fixedly connected to the side of the conveyor belt body (2). Cylinder clamps (21) are symmetrically installed on the mounting plate (20). A conveyor belt motor (22) is installed on the side of the conveyor belt body (2) away from the mounting plate (20). The output end of the conveyor belt motor (22) is connected to the conveyor belt body (2) in a transmission connection. The control cabinet (1) is equipped with a tin plating tank (3) and a cooling tank (4). The top of the conveyor belt body (2) is also equipped with a support frame (30). The support frame (30) is symmetrically equipped with telescopic cylinders (31) on the side of the support frame (30) near the tin plating tank (3). The telescopic ends of the two telescopic cylinders (31) are equipped with scrapers (32).
5. The processing technology of a surface-mount toroidal inductor according to claim 3, characterized in that, The position adjustment assembly also includes a vertical guide rail (5) symmetrically fixedly connected to the top of the control cabinet (1). A vertical threaded rod (50) is rotatably connected to the inner side of the vertical guide rail (5). The vertical threaded rod (50) is rotatably connected to the conveyor belt body (2). A first transmission sprocket (52) is fixedly connected to one end of the vertical threaded rod (50) extending to the outer side of the conveyor belt body (2). A first transmission chain (51) is sleeved between the two first transmission sprockets (52). One of the vertical threaded rods (50) is fixedly connected to the output end of a vertical drive motor (511) installed inside the conveyor belt body (2). The vertical lifting plate (53) is threadedly connected to the vertical threaded rod (50) and slides relative to the vertical guide rail (5). A slide rod (54) that slides relative to the vertical lifting plate (53) is symmetrically fixedly connected to the control cabinet (1).
6. The processing technology of a surface-mount toroidal inductor according to claim 5, characterized in that, The bottom of the vertical lifting plate (53) is symmetrically equipped with horizontal guide rails (55), and the inner side of the horizontal guide rails (55) is rotatably connected with horizontal threaded rods (56). Both horizontal threaded rods (56) are threadedly connected with threaded sliders (512) that slide relative to the horizontal guide rails (55). The two threaded sliders (512) are fixedly connected to the horizontal moving plate (57). A horizontal drive motor (58) is installed on the side of each of the two horizontal guide rails (55) that are far apart from each other. A second transmission sprocket (59) is installed on the output end of the horizontal drive motor (58) and the end of the horizontal threaded rod (56) that extends to the outside of the horizontal guide rail (55) and is close to the horizontal drive motor (58). A second transmission chain (510) is sleeved and connected between the two second transmission sprockets (59).
7. The fabrication process of a surface-mount toroidal inductor according to claim 3, characterized in that, The flipping clamping assembly also includes a flipping bracket (60) fixedly connected to the bottom of the horizontal moving plate (57). A directional rod (62) is rotatably connected to the inner side of the flipping bracket (60). The directional rod (62) is fixedly connected to the rotating seat (61). A directional motor (613) is installed on the side of the flipping bracket (60). A driving bevel gear (614) is fixedly connected to the output end of the directional motor (613). A driven bevel gear (615) is installed at the end of the directional rod (62) near the directional motor (613). The driven bevel gear (615) meshes with the driving bevel gear (614).
8. The fabrication process of a surface-mount toroidal inductor according to claim 7, characterized in that, A fixed cylinder (6) is fixedly connected to the side of the rotating seat (61). A support plate (610) is fixedly connected to the inner side of the fixed cylinder (6). A flip motor (611) is installed on the inner side of the fixed cylinder (6). A flip driven gear (617) is rotatably connected between the output end of the flip motor (611) and the support plate (610). Multiple transmission shafts (618) are rotatably connected to the support plate (610). A flip master gear (616) is installed on the transmission shaft (618). The flip master gear (616) is evenly distributed around the outside of the flip driven gear (617). The flip driven gear (617) meshes with the multiple flip master gears (616).
9. The processing technology of a surface-mount toroidal inductor according to claim 8, characterized in that, Multiple drive shafts (618) are fixedly connected to a universal joint (63) at one end away from the flip gear (617), and a rotating rod (670) is fixedly connected to the end of each universal joint (63) away from the drive shaft (618). The rotating rod (670) is fixedly connected to the clamping cylinder (67).
10. The fabrication process of a surface-mount toroidal inductor according to claim 9, characterized in that, The drive disk (68) has multiple drive grooves (680) circumferentially through it, and the limiting disk (69) has multiple limiting grooves (690) circumferentially through it. The rotating rod (670) has a bearing (612) installed on its outer surface at the drive groove (680) and the limiting groove (690). The bearing (612) slides relative to the drive groove (680) and the limiting groove (690). A gear ring (66) is fixedly installed on the outer side of the drive disk (68), and a pitch adjustment motor (64) is fixedly installed on the outer side of the fixed cylinder (6). An adjustment gear (65) that meshes with the gear ring (66) is fixedly installed at the output end of the pitch adjustment motor (64).