Coil shaping system and coil shaping method

Abstract

The invention provides a coil shaping system and a coil shaping method. The coil shaping system comprises a mold, a temperature control device and a water cooling device, the mold is used for winding a coil to be shaped, and the temperature control device comprises a power source and supplies power to the coil through the power source so that the coil can be shaped through heating of the coil; and the water cooling device is used for cooling the coil so as to cool the coil. According to the system, the mold and the coil do not need to be put into an oven, the power supply supplies power to the coil to be shaped, and the coil can be shaped by self-heating, so that the coil manufacturing time is shortened, the coil manufacturing energy consumption is reduced, and the coil manufacturing efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of coil manufacturing technology, and in particular to a coil shaping system and coil shaping method. Background Technology

[0002] The application of coils in etching equipment is becoming increasingly widespread. During the process, coils are used to control the magnetic field strength inside the process chamber to adjust the plasma direction, thereby improving wafer uniformity. However, as the volume of the process chamber gradually increases, the size of the coils has also gradually increased from a diameter of 100 mm. To better match the chamber environment, the coil size has increased to over 500 mm. Furthermore, as the requirements for adjustable magnetic field strength in etching equipment become increasingly stringent, the number of coil turns is becoming denser (i.e., smaller wire diameter, achieving more turns in the same space).

[0003] The existing method uses self-adhesive enameled wire to wind a multi-layered coil around a mold, and then places the mold and the coil together in an oven for high-temperature setting. However, due to the large size of the mold, the heating and cooling times are both long, which means that both the oven heating and cooling and the mold heating and cooling require a lot of time. At the same time, when moving the coil and the mold in and out of the oven, the mold is too heavy and needs to be hoisted. As a result, the existing coil manufacturing method has the disadvantages of high cost, low efficiency and long cycle, which affects the delivery of subsequent coil products. Summary of the Invention

[0004] In view of this, the purpose of the present invention is to provide a coil shaping system and a coil shaping method to alleviate at least some of the above-mentioned technical problems, reduce the coil manufacturing time and energy consumption, and improve the coil manufacturing efficiency.

[0005] In a first aspect, embodiments of the present invention provide a coil shaping system, the system comprising: a mold, a temperature control device, and a water cooling device; wherein, the mold is used to wind a coil to be shaped, the temperature control device includes a power supply, the power supply being electrically connected to the coil; the temperature control device is used to supply power to the coil through the power supply so that the coil can achieve shaping by utilizing its own heat; the water cooling device is used to provide cooling to the coil to reduce its temperature.

[0006] Preferably, the temperature control device includes: a control unit and a temperature detection unit communicatively connected to the control unit; wherein the control unit is also communicatively connected to a power supply; the temperature detection unit is used to detect the current temperature of the coil in real time and send the current temperature to the control unit; the control unit is used to acquire the current temperature and adjust the output current of the power supply according to the current temperature and a preset temperature so that the coil is heated and shaped.

[0007] Preferably, the water cooling device includes a water cooling plate and a flow control valve; wherein the flow control valve is communicatively connected to the control unit, and the water cooling plate is disposed above the mold; the control unit is also used to adjust the opening of the flow control valve according to the current temperature and the preset temperature, so as to adjust the flow rate of the cooling water in the water cooling plate to cool the coil.

[0008] Preferably, the control unit is further configured to: if the current temperature is less than a preset temperature, increase the output current of the control power supply and control the opening of the flow control valve to a preset opening; if the current temperature is equal to the preset temperature, keep the output current of the control power supply unchanged and control the opening of the flow control valve to a preset opening; if the current temperature is greater than the preset temperature, and the difference between the current temperature and the preset temperature is not greater than a first preset temperature difference, decrease the output current of the control power supply until it stops outputting, and control the opening of the flow control valve to increase.

[0009] Preferably, the control unit is further configured to generate an alarm message and control the power supply to stop output when the difference is greater than a first preset temperature difference; and to acquire the duration of the power supply's output stop, and control the flow control valve to close when the output stop duration reaches a first duration.

[0010] Preferably, the control unit is also configured to start timing when the current temperature first reaches the preset temperature, and when the timing duration reaches the second duration, control the power supply to stop outputting and control the opening degree of the flow control valve to the preset opening degree to cool the coil.

[0011] Preferably, the control unit is also used to acquire the cooling water temperature during the cooling process, and to control the flow control valve to close when the difference between the current temperature of the coil and the cooling water temperature is less than a second preset temperature difference.

[0012] Preferably, the temperature detection unit includes multiple temperature sensors; wherein the multiple temperature sensors include a first temperature sensor and a second temperature sensor; the first temperature sensor is used to detect a first temperature at the bottom position of the coil and send the first temperature to the control unit; the second temperature sensor is used to detect a second temperature at the middle position of the coil and send the second temperature to the control unit; the control unit is also used to acquire the first temperature and the second temperature, and calculate the current temperature of the coil based on the first temperature and the second temperature.

[0013] Preferably, the water cooling plate is provided with multiple water channels, each channel being used to supply cooling water to cool the coil.

[0014] Preferably, at least two clamps are also installed on the mold. The clamps are detachably disposed on the outside of the mold. The inner wall of the clamps and the outer wall of the mold form a limiting space, which is used to limit the relative position of the coil on the mold.

[0015] Secondly, embodiments of the present invention also provide a coil shaping method applied to the coil shaping system of the first aspect described above. The method includes: a temperature control device supplying power to the coil via a power source so that the coil can achieve shaping by utilizing its own heat; and a water cooling device providing cooling to the coil to reduce its temperature.

[0016] The embodiments of the present invention bring the following beneficial effects:

[0017] This invention provides a coil shaping system and method. A temperature control device supplies power to the coil, allowing the coil to achieve shaping by its own heat generation. A water cooling device provides cooling to the coil, thus eliminating the need to place the mold and coil in an oven. In other words, without moving the mold and coil, the coil to be shaped is supplied with power, and shaping is achieved by the coil's own heat generation. This reduces the coil manufacturing time and energy consumption, and improves the coil manufacturing efficiency.

[0018] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention are realized and obtained through the structures particularly pointed out in the description and the drawings.

[0019] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0020] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0021] Figure 1 A schematic diagram of a hollow coil provided in an embodiment of the present invention;

[0022] Figure 2 This is a schematic diagram of a coil shaping system provided in an embodiment of the present invention;

[0023] Figure 3 This is a schematic cross-sectional view of a self-adhesive enameled wire provided in an embodiment of the present invention;

[0024] Figure 4 A side view of a coil mold and fixture provided in an embodiment of the present invention;

[0025] Figure 5A top view of a coil mold and fixture provided in an embodiment of the present invention;

[0026] Figure 6 Another overall side view of the coil mold and fixture provided in an embodiment of the present invention;

[0027] Figure 7 A side cross-sectional view of a coil mold and fixture provided in an embodiment of the present invention;

[0028] Figure 8 A schematic diagram of a shaped coil provided in an embodiment of the present invention;

[0029] Figure 9 This is a schematic diagram of the water channel inside a water-cooling pan provided in an embodiment of the present invention;

[0030] Figure 10 This is a schematic diagram of another coil shaping system provided in an embodiment of the present invention;

[0031] Figure 11 This is a schematic diagram illustrating the working principle of a coil shaping system provided in an embodiment of the present invention.

[0032] Figure 12 A schematic diagram illustrating the relationship between the outer layer material and bonding temperature of a self-adhesive enameled wire provided in an embodiment of the present invention;

[0033] Figure 13 A flowchart of a coil shaping method provided in an embodiment of the present invention;

[0034] Figure 14 A flowchart of another coil shaping method provided in an embodiment of the present invention. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions 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, 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.

[0036] Traditional coil manufacturing is based on wire mold winding, which involves mechanically shaping copper wire to create hollow coils (without an inner core). As the number of turns increases, the wire diameter becomes increasingly smaller, and traditional copper tubes cannot meet the miniaturization requirements of multi-turn coils. Therefore, existing solutions have gradually evolved to use self-adhesive enameled wire. Self-adhesive enameled wire, also known as self-melting wire, is a special type of enameled wire with an additional layer of self-adhesive enamel coating on its surface. Once the self-adhesive layer melts, each turn of the coil is bonded together to form a hollow coil. Furthermore, coils wound with self-adhesive enameled wire exhibit thermal stability at high temperatures, and thermosetting self-adhesive layers have even higher heat resistance, only losing their adhesive strength after reaching the temperature that destroys the enamel film.

[0037] In the fabrication of multi-turn coils, a self-adhesive enameled wire is first wound around a mold. After the innermost layer of coil is wound, an outer layer is wound on top of the inner layer without any breaks, thus forming a multi-layered coil. For example, ... Figure 1 The two-layer coil shown has two layers (M) and 10 turns (N) in the same layer. Furthermore, since the self-adhesive enameled wire requires heat treatment to bond and shape after coil winding, the coil is prone to unmolding and falling apart before high-temperature setting. Therefore, the coil, along with the mold, must be placed in a high-temperature oven and baked at 150°C for at least 30 minutes to shape.

[0038] However, in the above-mentioned high-temperature shaping process, the mold is heated together with the coil. Due to the large size of the mold, the heating and cooling times are both long, which means that the heating and cooling of the oven and the mold take a lot of time. For example, the shaping time for a single coil is usually more than 4 hours. At the same time, when moving the coil and the mold in and out of the oven, the mold is too heavy (generally weighing more than 80kg, which cannot be moved manually) and needs to be hoisted. As a result, the existing coil manufacturing has the disadvantages of high cost, low efficiency and long cycle, which affects the delivery of subsequent coil products.

[0039] Based on this, embodiments of the present invention provide a coil shaping system and a coil shaping method, which eliminates the need to place the mold and coil in an oven, thereby achieving rapid coil shaping without moving the mold and coil position, thus reducing coil production time and energy consumption, and improving coil production efficiency.

[0040] To facilitate understanding of this embodiment, the embodiments of the present invention will be described in detail below.

[0041] Example 1

[0042] This invention provides a coil shaping system, such as... Figure 2As shown, the system includes: a mold 10, a temperature control device 20, and a water cooling device 30; wherein, the mold 10 is used to wind the coil 11 to be shaped, and the temperature control device 20 includes a power supply 23, which is electrically connected to the coil 11. Specifically, the temperature control device 20 is used to supply power to the coil 11 through the power supply 23 so that the coil 11 can achieve shaping by its own heat; the water cooling device 30 is used to cool the coil 11 to reduce its temperature.

[0043] Therefore, the system does not require placing the mold 10 and coil 11 in an oven. The coil 11 to be shaped is powered by the power supply 23, and the coil 11 can be shaped by its own heating. This reduces the production time and energy consumption of the coil 11 and improves the production efficiency of the coil 11.

[0044] The coil 11 can be of different sizes, and it is a hollow coil, meaning it has no inner core. The wire used is self-adhesive enameled wire, which is a conventional wire with an added coating material, such as... Figure 3 As shown, the self-adhesive enameled wire includes a resin layer 111, an insulation layer 112, and a wire core 113; wherein, the resin layer 111 is the outermost coating of the self-adhesive enameled wire, and the insulation layer 112 is the wire core insulation layer of the self-adhesive enameled wire, which is used to ensure that the wire core 113 is insulated from the outside world.

[0045] Before high-temperature setting, the self-adhesive enameled wire is relatively soft, and the coil is in a loose state. Therefore, a mold is needed to provide a model for coil winding; that is, the coil is wound based on the mold. At this time, the wire core 113 will always be in the middle part of the self-adhesive enameled wire. In addition, the wire core 113 is a single copper core, not multiple copper wires, and with the insulation layer 112 and resin layer 111 (which is in a hard state at room temperature), it is more rigid than ordinary cables. After the coil is wound based on the mold, if it is directly demolded, the coil will unravel. Therefore, before the coil is set, it needs to be fixed on the mold.

[0046] In one embodiment, at least two clamps are also installed on the mold. The clamps are detachably disposed on the outside of the mold, and the inner wall of the clamps and the outer wall of the mold form a limiting space. The limiting space is used to limit the relative position of the coil on the mold.

[0047] Specifically, such as Figures 4-7As shown, the clamp 12 is detachably mounted on the outside of the mold 10 to tightly fix the coil 11 to the mold 10, that is, to fix the coil 11 within the limiting space formed by the inner wall of the clamp 12 and the outer wall of the mold 10. In practical applications, firstly, the coil 11 is wound on the outside of the mold 10 according to actual needs (preset number of turns and preset number of layers); then, after winding, the coil 11 is fixed to the mold 10 by multiple clamps 12 mounted on the mold 10, such as fixing the upper and lower boundaries of the coil 11 by the clamps 12 to prevent the coil 11 from unraveling before shaping. Therefore, the clamps 12 cannot be removed before shaping to ensure that the coil 11 does not unravel before shaping; after shaping, the outer layer of the coil 11 hardens, at this time, the clamps 12 are removed to demold the coil 11, and the coil is completed, resulting in the coil 11. Figure 8 The coil after shaping is shown.

[0048] It should be noted that the molds 10 mentioned above are mostly cylindrical with grooves on the outside to provide the innermost wiring path for the coil. In addition, the molds 10 are mostly made of stainless steel, which generally has the characteristic of high temperature resistance, that is, it does not produce a chemical reaction with the outer layer of the enameled wire at high temperatures, thereby ensuring the safe shaping of the coil.

[0049] Furthermore, during the winding process, coil 11 may be wound in multiple layers, with different layers in a staggered state. For example, a later layer can be wound using the empty space between two adjacent turns of a previous layer as a positioning point, meaning the inner layer acts as the mold for the outer layer. For instance, if the preset number of layers is multiple, the first layer uses the slot on the outer side of the mold as the routing path, the second layer uses the empty space between adjacent turns of the first layer as a positioning point, and so on, until the preset number of layers is reached. Figure 1 The two layers are shown. It should be noted that the preset number of turns and preset number of layers can be set according to actual conditions, and the embodiments of the present invention do not impose any limitations on this.

[0050] In one implementation, such as Figure 2 As shown, the temperature control device 20 further includes a control unit 21 and a temperature detection unit 22 communicatively connected to the control unit 21; wherein, the control unit 21 is also communicatively connected to the power supply 23. It should be noted that the power supply 23 can be a DC power supply or an AC power supply, and the type of power supply is not limited in this embodiment of the invention.

[0051] Specifically, the temperature detection unit 22 is used to detect the current temperature T of the coil in real time and send the current temperature T to the control unit 21; the control unit 21 is used to acquire the current temperature T and adjust the output current of the power supply 23 according to the current temperature T and the preset temperature Tset, so as to heat and shape the coil. Since the power supply 23 supplies power to the coil 11 so that the coil 11 can use its own heat to shape, the control unit 21 can adjust the heating temperature of the coil 11 by adjusting the output current of the power supply 23 according to the current temperature T and the preset temperature Tset. This not only ensures the high-temperature shaping of the coil 11, but also increases the shaping rate of the coil 11, thereby reducing the coil manufacturing time and energy consumption, and improving the coil manufacturing efficiency.

[0052] In one implementation, such as Figure 2 As shown, the water cooling device 30 includes a water cooling plate 31 and a flow control valve 32; wherein, the flow control valve 32 is communicatively connected to the control unit 21, and the water cooling plate 31 is disposed above the mold 10; the control unit 21 is also used to adjust the opening of the flow control valve 32 according to the current temperature T and the preset temperature Tset, so as to adjust the flow rate of the cooling water in the water cooling plate 31 to cool the coil 11.

[0053] The water-cooling plate 31 is equipped with multiple water channels, each channel supplying cooling water to cool the coil 11. Specifically, as shown... Figure 9 As shown, 311 represents the cross-section of the water channel. Here, four water channels are used as an example, such as the first water channel 3111, the second water channel 3112, the third water channel 3113, and the fourth water channel 3114. Thus, the water cooling plate 31 provides cooling water through multiple water channels to cool the coil.

[0054] Since the wire used for winding the coil is enameled wire, the self-adhesive temperature range of conventionally used enameled wire is generally 150℃-200℃. Special enameled wire materials can withstand higher temperatures, but the self-adhesive layer has an upper limit. Exceeding this upper limit will damage the self-adhesive layer, causing it to lose its adhesiveness. High temperatures will also damage the insulation layer, leading to coil shaping failure or poor quality. Therefore, in the coil shaping process, the control unit adjusts the opening of the flow control valve based on the current coil temperature T and the preset temperature Tset. This adjusts the flow rate of cooling water supplied to the coil through multiple channels in the water-cooling pan. This not only provides a stable low temperature for the coil, preventing rapid temperature rise without water cooling, which could cause the coil temperature to exceed the upper limit of the coil material's tolerance and damage the outer layer of the enameled wire, but also allows for rapid cooling of the coil after shaping, shortening the natural cooling time and improving coil manufacturing efficiency.

[0055] Therefore, the coil shaping system provided in this embodiment of the invention does not require placing the mold and coil in an oven. That is, without moving the mold and coil, the coil is shaped by powering the coil with its own heat. At the same time, the coil is cooled by a water cooling device, which not only achieves rapid shaping of the coil, but also ensures safe shaping of the coil, avoids damage caused by high temperature, and shortens the natural cooling time of the coil after high temperature shaping. This reduces the coil production time and energy consumption, and improves the coil production efficiency.

[0056] In one embodiment, the control unit is further configured to: if the current temperature is less than a preset temperature, increase the output current of the control power supply and control the opening of the flow control valve to a preset opening; if the current temperature is equal to the preset temperature, keep the output current of the control power supply unchanged and control the opening of the flow control valve to a preset opening; if the current temperature is greater than the preset temperature, and the difference between the current temperature and the preset temperature is not greater than a first preset temperature difference, decrease the output current of the control power supply until it stops outputting, and control the opening of the flow control valve to increase.

[0057] Specifically, after obtaining the current temperature T of the coil, the control unit adjusts the output current of the power supply and / or the opening of the flow control valve based on the current temperature T and the preset temperature Tset. The adjustment process mainly falls into the following three categories:

[0058] (1) The current temperature is less than the preset temperature, i.e., T < Tset;

[0059] Specifically, in the coil shaping process, if the current temperature is lower than the preset temperature (T < Tset), it means that the current heating temperature of the coil has not yet reached the shaping temperature, and the coil needs to be heated further. Therefore, at this time, the control unit controls the output current of the power supply to increase so that the coil can continue to be heated. At the same time, the opening of the flow control valve is controlled to the preset opening to avoid the coil temperature from exceeding the upper limit of the temperature that the coil material can accept, which would cause damage to the outer layer of the enameled wire. In other words, the coil is heated rapidly while ensuring the quality of coil shaping.

[0060] It should be noted that the preset opening degree here is preferably 20% of the total opening degree of the flow control valve, so as to provide a basic cold source for the coil and prevent overheating due to lack of a cold source during the coil heating process, while also ensuring that the temperature can be reduced quickly. In addition, if the opening degree is set too large, the output current of the power supply will increase in order to heat the coil to the set temperature, thereby increasing the energy consumption of coil manufacturing. Therefore, the preset opening degree is preferably 20% of the full range, and the specific value can be adjusted according to the actual situation. Also, since the self-bonding temperature range of conventional enameled wire is generally 150℃-200℃, the above-mentioned set temperature is preferably 150℃. If the material of the enameled wire changes, the set temperature value can be adjusted according to the actual situation.

[0061] (2) The current temperature is equal to the preset temperature, i.e., T = Tset;

[0062] Specifically, when the current temperature of the coil is equal to the preset temperature, i.e., T = Tset, the coil has reached the shaping temperature and does not need to be heated. Therefore, the control unit keeps the output current of the power supply constant so that the coil can be shaped according to the set temperature. It also controls the opening of the flow control valve to the preset opening to avoid the coil temperature exceeding the upper limit of the coil material during the shaping process, which would damage the outer layer of the enameled wire and thus improve the manufacturing quality of the coil.

[0063] (3) The current temperature is greater than the preset temperature, i.e., T > Tset;

[0064] Specifically, in the coil shaping process, if the current temperature of the coil is greater than the preset temperature (T > Tset), the difference between the current temperature and the preset temperature is further calculated. If the difference is not greater than the first preset temperature difference, it indicates that the current heating temperature of the coil has exceeded the shaping temperature, but has not yet exceeded the upper temperature limit acceptable to the coil material. Therefore, the coil needs to be cooled down. The control unit controls the output current of the power supply to decrease until it stops outputting, and controls the opening of the flow control valve to increase, so that the coil temperature quickly returns to the set temperature, thereby ensuring the quality of coil shaping. It should be noted that the first preset temperature difference is preferably 20℃, but it can be adjusted adaptively according to the actual situation.

[0065] Therefore, in the coil shaping process, the current temperature of the coil is detected in real time by a temperature detection unit and fed back to the control unit. The control unit then adjusts the output current of the power supply and / or the opening of the flow control valve according to the current temperature and the set temperature. This allows for rapid coil shaping without placing the mold and coil in an oven, thereby reducing the coil production time and energy consumption and improving the coil production efficiency.

[0066] In one embodiment, the control unit is further configured to generate an alarm message and control the power supply to stop output when the difference is greater than a first preset temperature difference; and to acquire the duration of the power supply's output stop, and control the flow control valve to close when the output stop duration reaches a first duration.

[0067] Specifically, when the current temperature of the coil is greater than the preset temperature (T > Tset), if the difference between the current temperature and the preset temperature is greater than the first preset temperature difference, it indicates that the current heating temperature of the coil has exceeded the setting temperature and the upper limit of the temperature acceptable to the coil material. Therefore, the control unit generates an alarm message and stops the power supply to prevent the coil from being damaged due to high temperature, thus preventing setting failure. Furthermore, after the power supply stops, the flow control valve continues to maintain its current opening or increases to its maximum opening to increase the flow rate of cooling water in the water channel, thereby quickly cooling the coil. The cooling process can also be timed, with the duration of power supply shutdown representing the cooling duration. When the shutdown duration reaches the first set time, the flow control valve closes, thus preventing the coil from being damaged due to excessive temperature during the setting process and further ensuring the coil manufacturing effect. It should be noted that the first set time is preferably 10 minutes, but it can be set according to actual conditions.

[0068] In one embodiment, the control unit is further configured to start timing when the current temperature first reaches the preset temperature, and when the timing duration reaches the second duration, control the power supply to stop outputting and control the opening degree of the flow control valve to the preset opening degree to cool the coil.

[0069] Specifically, in the existing solution, the mold and coil need to be placed in an oven for high-temperature shaping. When the oven is heated, the mold also needs to be heated, resulting in a long heating time. After the coil temperature reaches the set temperature of 150°C, it needs to be maintained for a certain period of time, such as 30 minutes, before the coil and mold are cooled down. Since the heating and cooling of the oven and the mold both take a lot of time, the coil production time in the existing solution is long, such as 4 hours. The coil shaping system provided in this embodiment of the invention eliminates the need to place the mold and coil in an oven. Instead, it directly supplies power to the coil, allowing it to shape using its own heat. Therefore, during the shaping process, there is no need to consider the temperature rise of the mold; only the coil temperature needs to be directly monitored. When the current temperature of the coil reaches the set temperature of 150°C for the first time, the control unit starts timing. When the timing reaches the second set time, it indicates that the coil shaping is complete. At this point, the coil needs to be cooled down. The control unit stops the power supply output and controls the opening of the flow control valve to a preset opening to rapidly cool the coil, thereby shortening the natural cooling time of the coil and thus shortening the coil manufacturing time and improving the coil manufacturing efficiency.

[0070] It should be noted that the second duration mentioned above is not less than 30 minutes, preferably 30 minutes, but can be adjusted according to the actual situation.

[0071] Furthermore, the control unit is also used to acquire the cooling water temperature during the cooling process, and to control the flow control valve to close when the difference between the current temperature of the coil and the cooling water temperature is less than a second preset temperature difference.

[0072] Specifically, during the cooling process, the control unit also acquires the current coil temperature T and cooling water temperature T in real time. 水 And based on the current temperature T and cooling water temperature T 水 Determine if the cooling process has ended. That is, if TT 水 If the second preset temperature difference (preferably 5℃, which can be adjusted according to actual conditions) is less than the target temperature, it indicates that the coil cooling is complete. At this point, the flow control valve is closed to demold the coil. Conversely, if TT... 水 If the temperature difference is greater than or equal to the second preset temperature difference, it means that the coil cooling is not yet complete. The opening of the flow control valve needs to be controlled to the preset opening to continue cooling the coil until the cooling is complete.

[0073] Therefore, after the coil has been shaped at high temperature, the above-mentioned method of rapidly cooling the coil with cooling water significantly shortens the cooling time of the coil compared with the natural cooling method in the oven in the existing solution, thereby shortening the production time of the coil and improving the production efficiency of the coil.

[0074] In one embodiment, the temperature detection unit includes multiple temperature sensors; for example, the multiple temperature sensors include a first temperature sensor and a second temperature sensor; the first temperature sensor is used to detect a first temperature at the bottom position of the coil and send the first temperature to the control unit; the second temperature sensor is used to detect a second temperature at the middle position of the coil and send the second temperature to the control unit; the control unit is also used to acquire the first temperature and the second temperature, and calculate the current temperature of the coil based on the first temperature and the second temperature.

[0075] For a single-layer coil, the bottom position refers to the location of the bottommost turn, and the middle position refers to the location of the middle turn. Similarly, for a multi-layer coil, the bottom position is preferably the location of the bottom turn of the outermost layer, and the middle position is preferably the location of the middle turn of the outermost layer. Furthermore, to ensure uniform coil temperature during heating and prevent damage or failure to shape the coil due to excessively high or low temperatures in certain areas, the number of temperature sensors can be increased according to the coil size, as the number of turns and layers increases. The specific number of temperature sensors and their detection coil positions can be set according to actual conditions.

[0076] Therefore, in the case where multiple temperature sensors detect the coil temperature, the control unit can average the temperatures fed back by the multiple temperature sensors to obtain the current temperature of the coil. For example, in the case of the first and second temperature sensors, the current temperature of the coil T = (first temperature T1 + second temperature T2) / 2. In this case, for the current temperature being greater than the preset temperature (T > Tset), in addition to satisfying T - Tset ≤ the first preset temperature difference (20℃), it is also necessary to satisfy the first temperature T1 - Tset ≤ the third preset temperature difference, and the second temperature T2 - Tset ≤ the third preset temperature difference. Here, the third preset temperature difference > the first preset temperature difference. Since the highest temperature of the outer layer of the coil is currently 180℃ and the set temperature is 150℃, when the coil temperature exceeds the set temperature by 30℃, it is determined that the coil may be damaged. Therefore, the preferred third preset temperature difference is 30℃. The specific value of the third preset temperature difference can be adaptively adjusted according to the type of enameled wire.

[0077] Therefore, when T-Tset≤20℃, T1-Tset≤30℃, and T2-Tset≤30℃ are simultaneously satisfied, the control unit reduces the output current of the power supply until it stops outputting, and increases the opening of the flow control valve. Conversely, when T>Tset, but T-Tset>20℃, and / or T1-Tset>30℃, and / or T2-Tset>30℃, the control unit determines that the coil temperature is abnormal, generates an alarm message, stops the power supply output to cool the coil, and closes the flow control valve after a certain period of time, such as 10 minutes, to avoid damage to the coil during shaping, thereby ensuring the manufacturing quality of the coil.

[0078] It should be noted that for cases with multiple temperature sensors, the same principle applies as for cases with two temperature sensors, and will not be elaborated further in this embodiment of the invention.

[0079] Example 2

[0080] In practical applications, the control unit can preferably be a PLC (Programmable Logic Controller), or a temperature controller + host computer. Here, we take a temperature controller + host computer, a temperature detection unit including a first temperature sensor and a second temperature sensor, and a DC power supply as an example.

[0081] Specifically, after the coil is wound, without moving the mold, a temperature control device and a water cooling device are added directly to the mold to form a coil shaping system; for example... Figure 10As shown, the upper part is a side view of the coil shaping system, and the lower part is a top view of the coil shaping system. The system includes a mold 10, a coil 11, a temperature control device, and a water cooling device. The temperature control device includes a temperature controller 211, a host computer 212, a first temperature sensor 221, a second temperature sensor 222, a DC power supply 23, and a positive terminal 231 and a negative terminal 232 of the DC power supply. The water cooling device includes a water cooling plate 31, a flow control valve 32, and a water source 33. The water cooling plate 31 also includes a water channel section 311, a water outlet 312, a water inlet 313, and an outer water cooling layer 314. The mold 10 also includes a mold outer layer 101, and the coil 11 also includes a coil outer layer 111.

[0082] The working principle of the above-mentioned coil shaping system is as follows: Figure 11 As shown, the process includes the following steps: After confirming that the hardware connection is correct, the coil shaping process is initiated. Temperature controller 211 controls the water cooling device to start, with the cooling water temperature set to 20°C and the water flow rate set to a preset opening degree (i.e., 20% of the full range). After the shaping temperature (150°C) is set on the host computer 212, the device is confirmed to begin heating. At this time, the DC power supply 23 is controlled to output current, which gradually increases to the upper limit value Amax (Amax is preferably the smaller of the upper limit value of the DC power supply output current and the upper limit value of the current that the coil can carry, i.e., Amax = Min{upper limit value of the DC power supply output current, upper limit value of the current that the coil can carry}), so that the coil heats up rapidly. Meanwhile, the temperature controller 211 acquires the temperature feedback from the first temperature sensor 221 and the second temperature sensor 222, and issues control commands in real time based on the feedback temperature and the set temperature to control the output current of the DC power supply 23 and the opening of the flow control valve 32, so that the cooling water of the water source 33 flows to the water cooling plate 31 through the flow control valve 32, and cools the coil 11 through multiple water channels in the water cooling plate 31.

[0083] When the surface temperature of coil 11 first reaches the set temperature of 150℃, the host computer 212 starts timing, denoted as t. When the temperature of coil 11 exceeds the set value (150℃), the temperature controller 211 increases the opening of the flow control valve 32 to increase the cooling water flow, while simultaneously stopping the output of the DC power supply 23, allowing the temperature of coil 11 to drop to the set value. Afterward, the temperature controller 211 controls the output current of the DC power supply 23 and the cooling water flow to stabilize the temperature of the entire system. After t = 30 minutes, the DC power supply 23 is turned off, and the opening of the flow control valve 32 is controlled to the preset opening to continue cooling the entire system, allowing coil 11 and mold 10 to quickly cool to room temperature. During the cooling stage of coil 11, when the temperature difference between coil 11 and cooling water is less than 5℃, the flow control valve 32 is closed, completing the shaping and fabrication of coil 11.

[0084] It should be noted that in existing high-temperature setting methods, the coil is first wound onto a mold, and then the mold and coil are placed in an oven for high-temperature setting. The setting time varies depending on the oven's power. Furthermore, moving the coil into the oven requires hoisting, consuming significant manpower and resources. After placing the coil in the oven, the oven is heated. Since the mold also needs to be heated, the heating time is lengthy. Once the temperature stabilizes at 150℃, it needs to be maintained for 30 minutes before the coil is cooled. Because the coil temperature cannot be effectively monitored independently during this process, the mold heating time and the subsequent overall cooling time must be considered, resulting in a long overall coil production time, such as 2 or 4 hours. The coil setting system described above, however, supplies power to the coil via DC power, utilizing the coil's own heat for setting. It eliminates the need to consider oven and mold temperature adjustments; simply maintaining the coil temperature at 150℃ for at least 30 minutes is sufficient for setting. Therefore, compared to existing high-temperature setting methods, this significantly reduces coil production time and improves coil production efficiency.

[0085] Furthermore, throughout the entire control process of the aforementioned system, the host computer 212 and the temperature controller 211 communicate bidirectionally. Specifically, the host computer 212 sends temperature control start / stop commands and set temperatures to the temperature controller 211. The temperature controller 211 executes the commands sent by the host computer 212 and provides real-time feedback on the current temperature of the coil 11 and the operating status of the temperature controller 211 (including but not limited to running, stopping, temperature, and fault information). The DC power supply 23 receives commands from the temperature controller 211 to supply power to the coil 11, and simultaneously provides feedback on the power supply status (current, voltage, and fault information). The flow control valve 32 receives instructions from the temperature controller 211 to control the cooling water flow of the water cooling device, and at the same time feeds back the valve status (opening degree, flow rate, fault information, etc.) to the host computer 212. After the host computer 212 obtains the information fed back from the temperature controller 211, the DC power supply 23 and the flow control valve 32, it can not only issue control instructions as needed to control the corresponding hardware actions, but also promptly issue an alarm when a certain hardware fails, so as to prompt the operator to stop the coil production in time to avoid coil damage and failure of shaping.

[0086] It should be noted that in the above control process, the temperature controller 211 or the host computer 212 can use a dual-loop PID (Proportion Integral Differential) control for heating and cooling, or it can quickly issue commands through software algorithms to realize the start and stop of temperature control.

[0087] Furthermore, the outer layer material of the enameled wire used in coil manufacturing generally includes polyamide resin, polyvinyl butyral resin, and aromatic polyamide resin, such as... Figure 12As shown, the bonding temperature varies depending on the material. In this embodiment of the invention, polyamide resin is preferred, and the corresponding bonding temperature is 120℃-180℃. In actual production, in order to prevent the self-adhesive layer material from being damaged by excessively high temperature or the bonding force from being insufficient due to insufficient temperature, the intermediate temperature is generally selected for setting. Therefore, the preset temperature Tset is preferably 150℃, and the recommended setting time is preferably 30 minutes.

[0088] For example, taking a coil as an example, the coil diameter is approximately between 230mm and 260mm, the coil has 350 turns, 14*25 (14 layers, 25 turns per layer), the outer diameter of the enameled wire is selected as 0.726mm (maximum current withstand of 7A), the actual coil resistance after winding is 12.44Ω, and the coil weight is 400g. The DC power supply outputs 5A DC current, and the real-time power is: P = I 2 *R=5*5*12.44=311W; Heating for 5 minutes releases heat Q1=Pt=311*60*5=93300J. The main material of enameled wire is copper, and copper's specific heat capacity is 0.386*10 3 J / (kg*℃), the energy required for 400g of copper to heat the coil from 20℃ to 150℃ is: Q2 = specific heat capacity * mass * temperature difference = 0.386 * 10 3 *130*0.4=20072J. Since Q1 is much larger than Q2, the required temperature for coil shaping can be met by electric heating.

[0089] Furthermore, in actual testing, when a 5A current is applied without cooling, the surface temperature of the coil will exceed 220°C after 5 minutes of energization. Therefore, during the coil heating process, the flow control valve needs to be controlled to operate at the preset opening to prevent the coil from heating up rapidly without water cooling, which could cause the coil temperature to exceed the upper temperature limit that the coil material can withstand, resulting in damage to the outer layer of the enameled wire, thereby ensuring the shaping quality of the coil.

[0090] Example 3

[0091] Based on the above-mentioned coil shaping system, this embodiment of the invention also provides a coil shaping method, such as... Figure 13 As shown, the method includes the following steps:

[0092] In step S1302, the temperature control device supplies power to the coil so that the coil can achieve shaping by heating itself.

[0093] In step S1304, the water cooling device provides cooling to the coil to lower its temperature.

[0094] Therefore, the above-described coil shaping method, by changing the high-temperature shaping process of the coil, achieves rapid coil shaping without moving the coil and its mold, thus shortening the coil manufacturing time and reducing energy consumption in coil production. It should be noted that the specific steps described above can be found in the control process of the aforementioned coil shaping system, and will not be elaborated upon further in this embodiment of the invention.

[0095] For ease of understanding, here we will use Figure 10 Taking a coil shaping system as an example, the execution process of the coil shaping method is explained. Figure 14 As shown, it includes the following steps:

[0096] Step S1402: The coil shaping process is started. The temperature controller is set with a preset opening degree, a set temperature Tset, and the maximum current value that the coil can carry. Specifically, after the coil shaping process is started, the temperature controller controls the water cooling device to turn on, the cooling water temperature is 20°C, and the water flow rate is set to the preset opening degree (i.e., 20% of the full range). After the shaping temperature (150°C) is set on the host computer, the device is confirmed to start heating up. At this time, the DC power supply 23 is controlled to output current, and the current gradually increases to the maximum current value Amax that the coil can carry.

[0097] Step S1404: Calculate the current coil temperature T based on T1 and T2; where T1 is the temperature detected by the first temperature sensor and T2 is the temperature detected by the second temperature sensor, and take the average value of T1 and T2 as the current coil temperature T; and, based on the relationship between the current coil temperature T and the set temperature Tset, execute step S1406, step S1410, or step S1414.

[0098] Step S1406, T = Tset;

[0099] Step S1408: Control the output current of the DC power supply to remain constant, keep the opening of the flow control valve at the preset opening, and start timing t when T first reaches Tset;

[0100] Step S1410, T < Tset;

[0101] Step S1412: Increase the output current of the DC power supply to control the opening of the flow control valve to the preset opening.

[0102] Step S1414, T > Tset;

[0103] Step S1416: Determine whether the following conditions are met: T1-Tset > 30℃, and / or T2-Tset > 30℃, and / or T-Tset > 20℃; if yes, proceed to step S1418; if no, proceed to step S1420.

[0104] Step S1418: Generate coil temperature abnormality alarm information, control DC power supply output, and control flow control valve to close after 10 minutes;

[0105] Step S1420: Control the DC power supply to stop outputting and increase the opening of the flow control valve;

[0106] Step S1422, timing duration t = 30 min, then proceed to cooling down;

[0107] Step S1424: During the cooling process, the DC power supply is stopped from outputting, and the opening of the flow control valve is set to a preset opening.

[0108] Step S1426: Determine whether TT is satisfied. 水 If the temperature is <5℃, proceed to step S1428; otherwise, return to step S1424 to continue cooling the coil. Where T... 水 Indicates the cooling water temperature;

[0109] Step S1428: Close the flow control valve.

[0110] Therefore, the coil shaping method provided in this embodiment of the invention is a manufacturing process that uses the coil itself to heat up and shape the coil by energizing it. This eliminates the need to place the mold and the coil in an oven, thus achieving rapid coil shaping, reducing the coil manufacturing time and improving the coil manufacturing efficiency. In addition, this process only heats the coil and does not require heating the mold, thereby reducing the energy consumption in coil manufacturing.

[0111] The coil shaping method provided in this embodiment of the invention has the same technical features as the coil shaping system provided in the above embodiment, so it can also solve the same technical problems and achieve the same technical effects.

[0112] The computer program product of the coil shaping system and coil shaping method provided in the embodiments of the present invention includes a computer-readable storage medium storing program code. The instructions included in the program code can be used to execute the methods described in the preceding method embodiments. For specific implementation, please refer to the method embodiments, which will not be repeated here.

[0113] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the system and apparatus described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0114] Furthermore, in the description of the embodiments of the present invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention based on the specific circumstances.

[0115] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a processor-executable, non-volatile, computer-readable storage medium. Based on this understanding, the technical solution of this invention, essentially, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0116] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0117] Finally, it should be noted that the above-described embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit it. The scope of protection of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the technical scope disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A coil shaping system, characterized in that, The system includes: a mold, a temperature control device, and a water cooling device; wherein, the mold is used to wind a coil to be shaped, and the temperature control device includes a power supply, which is electrically connected to the coil; The temperature control device is used to supply power to the coil through the power source, so that the coil can achieve shaping by using its own heat. The water-cooling device is used to provide cooling to the coil to reduce its temperature.

2. The system according to claim 1, characterized in that, The temperature control device includes: a control unit and a temperature detection unit communicatively connected to the control unit; wherein the control unit is also communicatively connected to the power supply. The temperature detection unit is used to detect the current temperature of the coil in real time and send the current temperature to the control unit; The control unit is used to acquire the current temperature and adjust the output current of the power supply according to the current temperature and the preset temperature so as to heat and shape the coil.

3. The system according to claim 2, characterized in that, The water cooling device includes a water cooling plate and a flow control valve; wherein the flow control valve is communicatively connected to the control unit, and the water cooling plate is disposed above the mold; The control unit is also used to adjust the opening of the flow control valve according to the current temperature and the preset temperature, so as to adjust the flow rate of the cooling water in the water cooling plate to cool the coil.

4. The system according to claim 3, characterized in that, The control unit is also configured to, if the current temperature is less than the preset temperature, control the output current of the power supply to increase, and control the opening degree of the flow control valve to a preset opening degree. If the current temperature is equal to the preset temperature, the output current of the power supply is kept constant, and the opening degree of the flow control valve is controlled to be the preset opening degree. If the current temperature is greater than the preset temperature, and the difference between the current temperature and the preset temperature is not greater than the first preset temperature difference, the output current of the power supply is reduced to stop output, and the opening of the flow control valve is increased.

5. The system according to claim 4, characterized in that, The control unit is further configured to generate an alarm message and control the power supply to stop output when the difference is greater than the first preset temperature difference; and to obtain the duration of the power supply's output stop, and control the flow control valve to close when the output stop duration reaches a first duration.

6. The system according to claim 4 or 5, characterized in that, The control unit is also configured to start timing when the current temperature first reaches the preset temperature, and when the timing duration reaches a second duration, control the power supply to stop outputting and control the opening degree of the flow control valve to the preset opening degree to cool the coil.

7. The system according to claim 6, characterized in that, The control unit is also used to acquire the cooling water temperature during the cooling process, and to control the flow control valve to close when the difference between the current temperature of the coil and the cooling water temperature is less than a second preset temperature difference.

8. The system according to claim 2, characterized in that, The temperature detection unit includes multiple temperature sensors; wherein the multiple temperature sensors include a first temperature sensor and a second temperature sensor. The first temperature sensor is used to detect a first temperature at the bottom of the coil and send the first temperature to the control unit; The second temperature sensor is used to detect a second temperature at the middle position of the coil and send the second temperature to the control unit; The control unit is further configured to acquire the first temperature and the second temperature, and calculate the current temperature of the coil based on the first temperature and the second temperature.

9. The system according to claim 3, characterized in that, The water-cooling plate is provided with multiple water channels, each of which is used to supply cooling water to cool the coil.

10. The system according to claim 1, characterized in that, The mold is also equipped with at least two clamps, which are detachably disposed on the outside of the mold. The inner wall of the clamps and the outer wall of the mold form a limiting space, which is used to limit the relative position of the coil on the mold.

11. A coil shaping method, characterized in that, The method, applied to the coil shaping system according to any one of claims 1-10, comprises: The temperature control device supplies power to the coil via the power source, so that the coil can achieve shaping by its own heat generation; The water cooling device provides cooling to the coil to lower its temperature.

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