A fully automatic winding machine for winding a coil of a transformer

Abstract

This invention relates to the field of transformer processing, specifically to a fully automatic coil winding machine for surface-mount transformers. It includes a frame with a wire breakage protection mechanism at one end and a felt wire pressing assembly at its lower end. A straightening and feeding mechanism and a winding device are arranged sequentially on the side of the frame. A feeding vibratory plate is located beside the winding device. A magnetic ring feeding mechanism with a guide frame is located near the winding device from the vibratory plate. A discharging mechanism is located below the guide frame, and a waste wire trough is located on the side. A pressure roller assembly is located near the winding device from the guide frame, including a limiting rubber wheel and two supporting rubber wheels. The wire is guided by the felt wire pressing assembly, its status is monitored by the wire breakage protection mechanism, and then straightened by the straightening and feeding mechanism. The magnetic ring is fed by the feeding vibratory plate and the guide frame, and the pressure roller assembly drives the magnetic ring to rotate, completing the winding process. After winding, the discharging mechanism transfers the finished product, and waste wire is centrally processed through the waste wire trough. This equipment can improve the accuracy and efficiency of magnetic winding, ensure stable feeding, and is suitable for multi-specification production.

Description

Technical Field

[0001] This invention relates to the field of transformer processing, specifically to a fully automatic chip transformer coil winding machine. Background Technology

[0002] As electronic components become increasingly miniaturized and precise, the precision and efficiency requirements for winding the coils of surface mount transformers, as core components, are constantly rising, making fully automated winding machines crucial production equipment. However, existing surface mount transformer coil winding machines still have many technical shortcomings in practical applications, making it difficult to meet the demands of mass production.

[0003] Firstly, existing equipment generally adopts a design where the independent gripper mechanism and drive component are separate. This means that during processing, the existing equipment first clamps the magnetic ring with grippers, and then a separate drive component rotates the magnetic ring. To adapt to changes in winding angle, the grippers need to frequently adjust their clamping position. During this process, fluctuations in clamping force can easily cause deformation or axial displacement of the magnetic ring, leading to deviations in the number of winding turns and loosening of the coil, resulting in significant fluctuations in product yield. Furthermore, position adjustments require machine downtime, significantly increasing the processing cycle and reducing production efficiency, failing to meet the demands of high-precision and high-cycle production.

[0004] Secondly, in terms of the design of the unloading mechanism, existing equipment mostly relies on a single gripper cylinder to transfer the magnetic ring. Due to the residual wire tension on the surface of the magnetic ring after winding, and the fact that the gripper only applies clamping force from the side, the magnetic ring is prone to slippage and tilting, causing it to fall or be damaged during the transfer process. This not only increases the product scrap rate but also requires manual cleaning of fallen workpieces, further affecting production continuity. In addition, some equipment uses a rigid transmission structure for the unloading components, which is prone to impact during lifting, aggravating the wear of the magnetic ring and components and shortening the service life of the equipment.

[0005] In addition, existing winding machines have poor adaptability to magnetic rings of different thicknesses and wires of different diameters. For magnetic rings of different specifications, manual disassembly and replacement of the gripper positioning components and readjustment of clamping parameters are required, which is complex and time-consuming. For wires of different diameters, the wire feeding mechanism needs to be replaced with an appropriate channel component, which is too lengthy and makes it difficult to quickly respond to multi-variety, small-batch production orders. The equipment's applicability is limited, production flexibility is insufficient, and it increases the company's equipment investment and production costs.

[0006] The aforementioned defects result in significant shortcomings in the existing winding machines in terms of processing accuracy, production efficiency, and specification adaptability. Therefore, we need to design a fully automatic winding machine that can achieve integrated magnetic ring positioning and driving, stable feeding, and rapid adaptation to multiple product specifications to solve the industry's pain points. Summary of the Invention

[0007] Therefore, it is necessary to provide a fully automatic chip transformer coil winding machine to address the existing technical problems.

[0008] To solve the problems of the prior art, the technical solution adopted by the present invention is as follows:

[0009] A fully automatic chip transformer coil winding machine includes:

[0010] A wire breakage protection mechanism is installed at one end of the frame. A felt wire pressing assembly is installed at the lower end of the wire breakage protection mechanism. A wire straightening and feeding mechanism and a wire winder are installed in sequence on the side of the wire breakage protection mechanism.

[0011] A feeding vibratory plate is provided next to the winding machine. A magnetic ring feeding mechanism is provided on the side of the feeding vibratory plate near the winding machine to feed the magnetic rings in the feeding vibratory plate. The magnetic ring feeding mechanism includes a guide frame fixed to the frame. A discharge mechanism is provided below the magnetic ring feeding mechanism. A waste wire discharge trough is provided next to the discharge mechanism.

[0012] The guide frame is equipped with a pressure roller assembly that drives the magnetic ring to rotate at one end near the winding device. The pressure roller assembly includes a position-adjustable limiting rubber roller, and two bearing rubber rollers with the same direction of rotation are arranged below the limiting rubber roller.

[0013] Furthermore, ceramic pigtail rings are arranged in an equally spaced array on the side of the wire breakage protection mechanism.

[0014] Furthermore, the wire straightening and feeding mechanism includes a wire pressing and straightening mechanism located next to the wire breakage protection mechanism. The wire pressing and straightening mechanism straightens the wire. A four-channel wire feeding mechanism is located next to the wire pressing and straightening mechanism, and a wire pressing limit mechanism is located next to the four-channel wire feeding mechanism.

[0015] Furthermore, a base is fixedly connected to the lower end of the guide frame, and the base is fixedly connected to the frame. A pneumatic push rod is fixedly connected to the upper end of the base. When the pneumatic push rod is activated, it pushes the magnetic ring in the guide frame to move to the upper end of the bearing rubber wheel.

[0016] Furthermore, a main motor fixed to the frame is installed on the side of the guide frame, and a floating shaft is keyed to the output end of the main motor;

[0017] The floating shaft is fixedly connected to a main gear at the end away from the main motor. The main gear is rotatably connected to the base and is coaxially fixedly connected to a load-bearing rubber wheel.

[0018] Furthermore, a main side gear is rotatably arranged beside the main gear. The main side gear is rotatably connected to the base and meshes with the main gear. A secondary gear is rotatably arranged beside the main side gear. The secondary gear is rotatably connected to the base and meshes with the main side gear. The secondary gear is coaxially fixed to another bearing rubber wheel.

[0019] Furthermore, an adapter is provided on the top of the base, an auxiliary motor is fixedly connected to the upper end of the adapter, the output end of the auxiliary motor is set downward and fixedly connected to the main magnetic wheel, an auxiliary magnetic wheel is provided at the lower end of the adapter, and the main magnetic wheel and the auxiliary magnetic wheel are connected by magnetic force transmission.

[0020] The auxiliary magnetic wheel is coaxially fixed to the assembly gear. The lower end of the assembly gear is provided with a reversing gear that is rotatably connected to the adapter. The reversing gear meshes with the assembly gear. The lower end of the reversing gear is provided with a limiting gear that is rotatably connected to the adapter. The limiting gear is coaxially fixed to the limiting rubber wheel.

[0021] Furthermore, a pneumatic swing arm is installed on the side of the guide frame. The output end of the pneumatic swing arm is fixedly connected to the adapter seat. When the pneumatic swing arm is started, it drives the adapter seat to move vertically.

[0022] Furthermore, the feeding mechanism includes a curved frame located at the lower end of the frame, a transfer frame fixedly connected to one end of the curved frame, a power motor fixedly connected to the lower end of the transfer frame, and a cam fixedly connected to the output end of the power motor on the same axis.

[0023] A rocker arm is hinged to the middle of the adapter frame via a torsion spring. A roller is rotatably connected to the lower end of the rocker arm, and the roller abuts against a cam. A pressure rod is fixed to the upper end of the rocker arm, and a gripper cylinder fixed to the upper end of the adapter frame is provided on the side of the pressure rod.

[0024] Furthermore, the feeding mechanism also includes a positioning frame fixedly connected to the lower end of the frame, and a secondary motor is fixedly connected to the lower end of the positioning frame;

[0025] The output end of the secondary motor is coaxially fixed to the main pulley. Above the main pulley is a secondary pulley that is rotatably connected to the positioning frame. The secondary pulley and the main pulley are connected by belt drive. The other end of the curved frame is fixed to the belt and slidably connected to the positioning frame.

[0026] The beneficial effects of this invention compared to the prior art are:

[0027] Firstly, this device integrates magnetic ring positioning and driving by using a pressure roller assembly consisting of a limiting rubber wheel and two unidirectional bearing rubber wheels. This eliminates the need for an additional gripper mechanism. The limiting rubber wheel, together with the two bearing rubber wheels, clamps the magnetic ring at three points. The synchronous rotation of both wheels drives the magnetic ring to rotate at a uniform speed. During the winding process, there is no need to change the clamping position, avoiding magnetic ring deformation and displacement caused by fluctuations in clamping force. At the same time, it eliminates downtime for position adjustment, improves the processing accuracy and production efficiency of the magnetic ring, and solves the problem of large fluctuations in the yield rate of existing equipment.

[0028] Secondly, the unloading mechanism in this device uses a pressure rod and a gripper cylinder for coordinated clamping. After the pressure rod deflects, it moves vertically from the upper limit magnetic ring, and the gripper clamps stably from the side, solving the defect of easy slippage and tilting when gripping alone in existing devices. At the same time, with the belt drive driven by the secondary motor, the curved frame can be raised and lowered smoothly and accurately positioned for unloading. This reduces the rate of magnetic ring falling and deflection during the transfer process, reduces product damage caused by unloading errors, lowers production costs, and avoids damage to the magnetic ring during transfer, further ensuring product quality.

[0029] Thirdly, the pneumatic swing arm of the pressure roller assembly in this device can adjust the height of the limiting rubber wheel to accommodate magnetic rings of different thicknesses, while the four-channel wire feeding mechanism can quickly switch wire feeding channels to accommodate wires of different diameters. The actions of each mechanism are automatically and collaboratively controlled, eliminating the need for frequent manual parameter adjustments. Compared with existing equipment that requires repeated adjustment of gripper parameters for different specifications of magnetic rings, this device shortens the switching time and reduces operational complexity, meeting the needs of mass production of multiple types of transformers. The applicability of the equipment is expanded, improving production flexibility and market adaptability. Attached Figure Description

[0030] Figure 1 This is a three-dimensional structural diagram of an embodiment;

[0031] Figure 2 This is a three-dimensional structural schematic diagram from another angle of the embodiment;

[0032] Figure 3 yes Figure 2 Enlarged view of the structure at point A in the middle;

[0033] Figure 4 yes Figure 2 Enlarged view of the structure at point B in the middle;

[0034] Figure 5 This is a three-dimensional structural diagram of the winding device and the magnetic ring feeding mechanism in the embodiment;

[0035] Figure 6 yes Figure 5 A three-dimensional structural breakdown diagram;

[0036] Figure 7 This is an exploded three-dimensional structural diagram of the feeding mechanism in the embodiment;

[0037] Figure 8 This is an exploded three-dimensional structural diagram of the pressure roller assembly in the embodiment;

[0038] Figure 9 yes Figure 6 Enlarged view of the structure at point C;

[0039] Figure 10 yes Figure 8 Enlarged view of the structure at point D.

[0040] The numbers on the map are:

[0041] 1. Frame; 2. Felt pressing assembly; 3. Wire breakage protection mechanism; 4. Ceramic pig tail ring; 5. Wire straightening and feeding mechanism; 6. Pressing and straightening mechanism; 7. Four-channel wire feeding mechanism; 8. Pressing limit mechanism; 9. Winder; 10. Waste wire chute; 11. Feeding vibratory plate; 12. Magnetic ring feeding mechanism; 13. Guide frame; 14. Pneumatic push rod; 15. Base; 16. Pressing roller assembly; 17. Main motor; 18. Floating shaft; 19. Main gear; 20. Main side gear; 21. Auxiliary gear ; 22. Bearing rubber wheel; 23. Pneumatic swing arm; 24. Adapter seat; 25. Auxiliary motor; 26. Main magnetic wheel; 27. Auxiliary magnetic wheel; 28. Assembly gear; 29. ​​Reversing gear; 30. Limit gear; 31. Limiting rubber wheel; 32. Unloading mechanism; 33. Positioning frame; 34. Secondary motor; 35. Main pulley; 36. Auxiliary pulley; 37. Curved frame; 38. Adapter frame; 39. Power motor; 40. Cam; 41. Roller; 42. Swing arm; 43. Pressure rod; 44. Gripper cylinder. Detailed Implementation

[0042] To further understand the features, technical means, and specific objectives and functions achieved by the present invention, the present invention will be described in further detail below with reference to the accompanying drawings and specific embodiments.

[0043] refer to Figures 1 to 10 A fully automatic chip transformer coil winding machine, comprising:

[0044] A wire breakage protection mechanism 3 is installed at one end of the frame 1. A felt wire pressing assembly 2 is installed at the lower end of the wire breakage protection mechanism 3. A wire straightening and feeding mechanism 5 and a wire winder 9 are installed on the side of the wire breakage protection mechanism 3 in sequence.

[0045] A feeding vibratory plate 11 is provided on the side of the winding machine 9. A magnetic ring feeding mechanism 12 is provided on the side of the feeding vibratory plate 11 near the winding machine 9 to feed the magnetic rings in the feeding vibratory plate 11. The magnetic ring feeding mechanism 12 includes a guide frame 13 fixedly connected to the frame 1. A discharge mechanism 32 is provided below the magnetic ring feeding mechanism 12. A waste wire discharge trough 10 is provided on the side of the discharge mechanism 32.

[0046] The guide frame 13 is provided with a pressure roller assembly 16 that drives the magnetic ring to rotate at one end near the winder 9. The pressure roller assembly 16 includes a position-adjustable limiting rubber roller 31, and two bearing rubber rollers 22 with the same direction of rotation are provided below the limiting rubber roller 31.

[0047] When the device is running, the wire is guided by the felt pressing assembly 2 and then moves from the wire breakage protection mechanism 3 to the straightening and feeding mechanism 5 for limiting and straightening. During the above process, the wire breakage protection mechanism 3 is used to monitor the status of the wire in real time during the conveying process to ensure that the wire can be grabbed in time after it breaks. The straightening and feeding mechanism 5 ensures that the wire will not be loose during the movement and will not affect the subsequent winding work.

[0048] When the wire moves to the winder 9, the magnetic ring feeding mechanism 12 is activated. Then, the magnetic ring in the feeding vibratory plate 11 moves to the side of the winder 9 via the guide frame 13. At this time, the pressure roller assembly 16 axially limits the magnetic ring and drives it to rotate. During this process, the two bearing rubber rollers 22 support the lower part of the magnetic ring, while the limiting rubber roller 31 presses the upper end of the magnetic ring from top to bottom. The materials of the bearing rubber roller 22 and the limiting rubber roller 31 ensure that the magnetic ring will not deform due to compression. Then, the bearing rubber roller 22 and the limiting rubber roller 31 rotate, thereby driving the magnetic ring to rotate. At this time, the winder 9 can wind the wire around the outside of the magnetic ring.

[0049] After the magnetic winding is completed, the unloading mechanism 32 starts and drives the finished product away from the processing station. The waste wire generated during the winding process will slide down the waste wire unloading trough 10 for easy centralized processing by the operator.

[0050] To allow the wire to turn at multiple angles and prevent breakage caused by sharp bending, the following features are specifically designed:

[0051] like Figure 3 As shown, ceramic pig tail rings 4 are arranged in an equally spaced array on the side of the wire breakage protection mechanism 3.

[0052] Along the path of the wire conveying from the wire breakage protection mechanism 3 to the straightening and feeding mechanism 5, the inner diameter of the ceramic pigtail ring 4 is precisely matched to the wire diameter. When the wire passes through the ceramic pigtail ring 4, the natural insulation of the ceramic material prevents static electricity from attracting dust, and the smooth ceramic inner wall avoids wear on the wire insulation layer. At the same time, the arc-shaped inner hole of the ceramic pigtail ring 4 can guide the wire to achieve multi-angle turning. When the winding device 9 drives the wire to change the conveying direction, the ceramic pigtail ring 4 can buffer the turning stress, prevent the wire from creases or breakage due to hard bending, ensure the integrity of the wire during the conveying process, and provide a stable wire supply for subsequent straightening and winding.

[0053] To further refine the specific structure of the wire straightening and conveying mechanism 5, and thereby achieve the straightening and conveying of the wire, the following features are also included:

[0054] like Figure 1 and Figure 4As shown, the wire straightening and feeding mechanism 5 includes a wire pressing and straightening mechanism 6 located next to the wire breakage protection mechanism 3. The wire pressing and straightening mechanism 6 straightens the wire. A four-channel wire feeding mechanism 7 is located next to the wire pressing and straightening mechanism 6, and a wire pressing limit mechanism 8 is located next to the four-channel wire feeding mechanism 7.

[0055] The wire straightening mechanism 6 applies uniform pressure to the wire as it passes through, eliminating slack sections and bending stress. The wire then enters the four-channel wire feeding mechanism 7, where four parallel channels drive the wire to be fed stably through friction. The four-channel design can accommodate wires of different diameters without the need for frequent component replacements. Finally, the wire passes through the limiting hole of the wire pressing and limiting mechanism 8, which prevents it from shifting due to vibration and ensures that it enters the winding machine 9 station accurately.

[0056] In order to push the magnetic ring falling along the guide frame 13 to the side where the limiting rubber wheel 31 and the two carrying rubber wheels 22 are close together, the following features are also provided:

[0057] like Figure 5 and Figure 9 As shown, a base 15 is fixedly connected to the lower end of the guide frame 13. The base 15 is fixedly connected to the frame 1. A pneumatic push rod 14 is fixedly connected to the upper end of the base 15. When the pneumatic push rod 14 is started, it pushes the magnetic ring in the guide frame 13 to move to the upper end of the bearing rubber wheel 22.

[0058] The guide frame 13 has a guide groove inside that matches the outer diameter of the magnetic ring. After the magnetic ring enters the guide groove from the feeding vibrating plate 11, it slides down the groove to the initial position near the bearing rubber roller 22. When the winding device 9 is ready, the pneumatic push rod 14 on the base 15 receives a signal, and the piston rod of the pneumatic push rod 14 extends horizontally. Then, the piston rod abuts against the end face of the magnetic ring and pushes the magnetic ring to move until the magnetic ring falls precisely onto the upper end of the two bearing rubber rollers 22, and the axis of the magnetic ring is parallel to the axis of the bearing rubber roller 22. This prepares for the positioning and driving of the subsequent pressure roller assembly 16 and avoids the magnetic ring getting stuck in the guide frame 13.

[0059] To further refine the specific structure of the pressure roller assembly 16 and thereby enable the drive of the main gear 19, the following features are also provided:

[0060] like Figure 6 , Figure 9 and Figure 10 As shown, a main motor 17 fixedly connected to the frame 1 is provided on the side of the guide frame 13, and a floating shaft 18 is keyed to the output end of the main motor 17.

[0061] The floating shaft 18 is fixedly connected to a main gear 19 at the end away from the main motor 17. The main gear 19 is rotatably connected to the base 15 and is coaxially fixedly connected to a bearing rubber wheel 22.

[0062] The output end of the main motor 17 is connected to the flexible floating shaft 18 via a coupling. The floating shaft 18 can buffer the impact of starting torque and prevent damage to the transmission components. The other end of the floating shaft 18 is fixedly connected to the main gear 19 via a flat key. The main gear 19 is rotatably connected to the base 15 via a bearing and is coaxially fixedly connected to a bearing rubber wheel 22. When the main motor 17 starts, the torque is transmitted sequentially through the floating shaft 18 and the main gear 19 to the bearing rubber wheel 22, driving it to rotate and providing a stable power foundation for the magnetic ring drive.

[0063] To enable the two load-bearing rubber wheels 22 to rotate in the same direction, the following features are specifically provided:

[0064] like Figure 9 and Figure 10 As shown, a main side gear 20 is rotatably arranged beside the main gear 19. The main side gear 20 is rotatably connected to the base 15 and meshes with the main gear 19. A secondary gear 21 is rotatably arranged beside the main side gear 20. The secondary gear 21 is rotatably connected to the base 15 and meshes with the main side gear 20. The secondary gear 21 is coaxially fixed to another bearing rubber wheel 22.

[0065] When the main gear 19 rotates, it drives the main side gear 20 to rotate in the opposite direction. The main side gear 20 then drives the auxiliary gear 21 to rotate in the opposite direction. Through two reverse transmissions, the two bearing rubber wheels 22 rotate in the same direction, ensuring that the magnetic ring rotates smoothly and avoiding the magnetic ring from getting stuck due to opposite rotation.

[0066] In order to achieve the rotation of the limiting rubber wheel 31, the following features are also provided:

[0067] like Figure 9 and Figure 10 A base 15 is provided with an adapter 24 above it. An auxiliary motor 25 is fixedly connected to the upper end of the adapter 24. The output end of the auxiliary motor 25 is set downward and fixedly connected to the main magnetic wheel 26. An auxiliary magnetic wheel 27 is provided at the lower end of the adapter 24. The main magnetic wheel 26 and the auxiliary magnetic wheel 27 are connected by magnetic transmission.

[0068] The auxiliary magnetic wheel 27 is coaxially fixed to the assembly gear 28. The lower end of the assembly gear 28 is provided with a reversing gear 29 that is rotatably connected to the adapter 24. The reversing gear 29 meshes with the assembly gear 28. The lower end of the reversing gear 29 is provided with a limiting gear 30 that is rotatably connected to the adapter 24. The limiting gear 30 is coaxially fixed to the limiting rubber wheel 31.

[0069] When the auxiliary motor 25 starts, it drives the main magnetic wheel 26 to rotate. The main magnetic wheel 26 then drives the auxiliary magnetic wheel 27 to rotate via magnetic force, which avoids mechanical wear and overload of the auxiliary motor 25. Subsequently, the auxiliary magnetic wheel 27 drives the reversing gear 29 to rotate via the assembly gear 28. The reversing gear 29 drives the limiting rubber wheel 31 to rotate via the limiting gear 30. At this time, the limiting rubber wheel 31 rotates synchronously with the two bearing rubber wheels 22, ensuring stable rotation speed of the magnetic ring.

[0070] In order to drive the limiting rubber wheel 31 to move closer to the two bearing rubber wheels 22, thereby clamping the magnetic ring and preventing the magnetic ring from shifting during winding, the following features are specifically provided:

[0071] like Figure 8 and Figure 9 As shown, a pneumatic swing arm 23 is provided on the side of the guide frame 13. The output end of the pneumatic swing arm 23 is fixedly connected to the adapter 24. When the pneumatic swing arm 23 is started, it drives the adapter 24 to move vertically.

[0072] After the magnetic ring is in place, the pneumatic swing arm 23 moves downward, causing the adapter seat 24 and the limiting rubber wheel 31 to move downward until the limiting rubber wheel 31 is in contact with the upper surface of the magnetic ring, applying appropriate clamping force. After winding is completed, the pneumatic swing arm 23 moves upward, and the limiting rubber wheel 31 moves upward to release the clamping force, making room for unloading. Through pneumatic control, the clamping force and displacement of the limiting rubber wheel 31 can be precisely adjusted to adapt to magnetic rings of different thicknesses, ensuring a stable clamping effect.

[0073] To facilitate clamping of the workpiece after machining, the following features are specifically designed:

[0074] refer to Figure 5 , Figure 6 and Figure 7 The feeding mechanism 32 includes a curved frame 37 disposed at the lower end of the frame 1. One end of the curved frame 37 is fixedly connected to a transfer frame 38. The lower end of the transfer frame 38 is fixedly connected to a power motor 39. The output end of the power motor 39 is coaxially fixedly connected to a cam 40.

[0075] A rocker arm 42 is hinged to the middle of the adapter frame 38 via a torsion spring. A roller 41 is rotatably connected to the lower end of the rocker arm 42. The roller 41 abuts against the cam 40. A pressure rod 43 is fixedly connected to the upper end of the rocker arm 42. A gripper cylinder 44 fixedly connected to the upper end of the adapter frame 38 is provided on the side of the pressure rod 43.

[0076] After winding is completed, the power motor 39 starts and drives the cam 40 to rotate. The protruding part of the cam 40 pushes the roller 41 to move upward, causing the rocker arm 42 to tilt upward around the hinge point of the adapter frame 38 (the torsion spring is stretched and stored). The pressure rod 43 moves upward simultaneously and presses against the upper end face of the magnetic ring, achieving initial positioning. Then, the gripper cylinder 44 starts, and the two output ends of the gripper cylinder 44 clamp the magnetic ring from both sides. The reason for setting the pressure rod 43 is that when only the gripper cylinder 44 is used, the residual wire tension on the magnetic ring and the side clamping can easily cause tilting and slippage. The pressure rod 43 limits the vertical displacement of the magnetic ring from above, and works with the two output ends of the gripper cylinder 44 to achieve stable clamping and prevent it from falling or shifting during transfer. After unloading, the power motor 39 rotates in the opposite direction, the torsion spring pulls the rocker arm 42 to reset, and the pressure rod 43 and the two output ends of the gripper cylinder 44 return to the initial state synchronously.

[0077] In order to drive the curved frame 37 to make vertical displacement, the following features are also provided:

[0078] refer to Figure 5 , Figure 6 and Figure 7 The feeding mechanism 32 also includes a positioning frame 33 fixedly connected to the lower end of the frame 1, and a secondary motor 34 is fixedly connected to the lower end of the positioning frame 33.

[0079] The output end of the secondary motor 34 is coaxially fixed to the main pulley 35. Above the main pulley 35 is a secondary pulley 36 that is rotatably connected to the positioning frame 33. The secondary pulley 36 and the main pulley 35 are connected by belt drive. The other end of the curved frame 37 is fixed to the belt and slidably connected to the positioning frame 33.

[0080] After the magnetic ring is gripped at the two output ends of the gripper cylinder 44, the secondary motor 34 starts and drives the main pulley 35 to rotate. The main pulley 35 drives the auxiliary pulley 36 to rotate synchronously via a belt. One end of the curved frame 37 is fixed to the belt and slidably connected to the positioning frame 33 via a slide rail (the positioning frame 33's slide groove restricts the direction of movement). The belt drives the curved frame 37 to move vertically downward along the slide groove. When the curved frame 37 reaches the unloading station, the two output ends of the gripper cylinder 44 open to place the magnetic ring. Then, the secondary motor 34 rotates in the opposite direction, and the curved frame 37 moves upward along the slide groove to reset, waiting for the next unloading. Belt drive enables the curved frame 37 to rise and fall smoothly and be precisely positioned, avoiding damage to the magnetic ring during transfer.

[0081] The detailed working principle of this device is as follows:

[0082] After powering on, the operator will pass the wire through the ceramic pigtail ring 4, the wire breakage protection mechanism 3, and the wire straightening and feeding mechanism 5 in sequence, and finally through the winding shaft of the winder 9; at the same time, the magnetic ring will be poured into the feeding vibrating plate 11. The vibrating plate will transport the magnetic ring to the guide groove of the guide rack 13 in a unified direction through high-frequency vibration. The magnetic ring will slide down the groove to the initial position above the base 15, and each mechanism will enter the standby state.

[0083] The wire breakage protection mechanism 3 monitors the wire tension and integrity in real time. If the wire breaks, its clamping component immediately closes to grab the wire end, preventing the wire from falling. When the wire passes through the ceramic pigtail ring 4, the arc-shaped inner hole guides the wire to adapt to the winding device 9 and avoids hard bending. After entering the wire pressing and straightening mechanism 6, the wire pressing and straightening mechanism 6 applies uniform pressure to eliminate wire slack and bending stress. Subsequently, the driving wheel and driven wheel of the four-channel wire feeding mechanism 7 drive the wire to be transported stably through friction, and the channel adapted to the wire diameter ensures smooth wire feeding. Finally, the limiting hole of the wire pressing and limiting mechanism 8 positions the wire laterally to ensure that it enters the winding device 9 accurately.

[0084] After the winding device 9 is ready, the magnetic ring feeding mechanism 12 is activated, the piston rod of the pneumatic push rod 14 extends and pushes the magnetic ring to the upper end of the two bearing rubber wheels 22; then the telescopic end of the pneumatic swing arm 23 moves down, driving the limiting rubber wheel 31 to press the magnetic ring to achieve axial positioning; at the same time, the main motor 17 is activated, and the torque is transmitted to one of the bearing rubber wheels 22 through the floating shaft 18 and the main gear 19. The main gear 19 drives the main side gear 20 to rotate in the opposite direction, and the main side gear 20 then drives the auxiliary gear 21 to rotate in the opposite direction, so that the other bearing rubber wheel 22 rotates in the same direction; the auxiliary motor 25 is activated synchronously, and through the magnetic transmission of the auxiliary magnetic wheel 27 and the gear set, it drives the limiting rubber wheel 31 and the bearing rubber wheel 22 to rotate synchronously, and finally drives the magnetic ring to rotate at a constant speed.

[0085] The winding device 9 starts according to preset parameters and drives the wire to wind around a magnetic ring that rotates at a uniform speed. The four-channel wire feeding mechanism 7 adjusts the wire feeding rate in real time according to the winding speed to ensure stable wire supply and uniform tension. Waste wire generated during the winding process falls naturally and is collected in a waste wire feeding trough 10 for subsequent unified processing, avoiding the accumulation of waste wire that affects equipment operation.

[0086] After winding is completed, the auxiliary motor 25 and the main motor 17 stop, and the limiting rubber wheel 31 and the carrying rubber wheel 22 stop rotating; the telescopic end of the pneumatic swing arm 23 moves upward, and the limiting rubber wheel 31 releases its pressure on the magnetic ring; the power motor 39 starts and drives the cam 40 to rotate, the pressure rod 43 moves upward and presses against the magnetic ring for positioning, and the gripper cylinder 44 clamps the magnetic ring; the secondary motor 34 starts and drives the curved frame 37 to move vertically downward along the slide groove of the positioning frame 33 to the unloading station through belt transmission; finally, the secondary motor 34 rotates in the opposite direction, the curved frame 37 moves upward and resets, the power motor 39 drives the cam 40 to rotate in the opposite direction, and the swing arm 42 and the pressure rod 43 reset under the action of the torsion spring, the device returns to the initial state, and waits for the next processing cycle to realize fully automatic continuous winding operation.

[0087] The above embodiments only illustrate one or more implementations of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this patent should be determined by the appended claims.

Claims

1. A fully automatic surface mount transformer coil winding machine, characterized in that, include: A wire breakage protection mechanism (3) is set at one end of the frame (1). A felt wire pressing assembly (2) is set at the lower end of the wire breakage protection mechanism (3). A wire straightening and feeding mechanism (5) and a wire winder (9) are set on the side of the wire breakage protection mechanism (3). A feeding vibratory plate (11) is provided on the side of the winding machine (9). A magnetic ring feeding mechanism (12) is provided on the side of the feeding vibratory plate (11) near the winding machine (9) to feed the magnetic ring in the feeding vibratory plate (11). The magnetic ring feeding mechanism (12) includes a guide frame (13) fixedly connected to the frame (1). A discharge mechanism (32) is provided below the magnetic ring feeding mechanism (12). A waste wire discharge trough (10) is provided on the side of the discharge mechanism (32). The guide frame (13) is provided with a pressure roller assembly (16) that drives the magnetic ring to rotate at one end near the winder (9). The pressure roller assembly (16) includes a position-adjustable limiting rubber wheel (31), and two bearing rubber wheels (22) with the same direction of rotation are provided below the limiting rubber wheel (31). The feeding mechanism (32) includes a curved frame (37) set at the lower end of the frame (1), a transfer frame (38) is fixedly connected to one end of the curved frame (37), a power motor (39) is fixedly connected to the lower end of the transfer frame (38), and a cam (40) is fixedly connected to the output end of the power motor (39) on the same axis. A rocker arm (42) is hinged to the middle of the adapter (38) by a torsion spring. A roller (41) is rotatably connected to the lower end of the rocker arm (42). The roller (41) abuts against the cam (40). A pressure rod (43) is fixedly connected to the upper end of the rocker arm (42). A gripper cylinder (44) fixedly connected to the upper end of the adapter (38) is provided on the side of the pressure rod (43). The feeding mechanism (32) also includes a positioning frame (33) fixedly connected to the lower end of the frame (1), and a secondary motor (34) is fixedly connected to the lower end of the positioning frame (33). The output end of the secondary motor (34) is coaxially fixed to the main pulley (35). Above the main pulley (35) is a secondary pulley (36) that is rotatably connected to the positioning frame (33). The secondary pulley (36) is connected to the main pulley (35) by belt drive. The other end of the curved frame (37) is fixed to the belt and slidably connected to the positioning frame (33).

2. The fully automatic chip transformer coil winding machine according to claim 1, characterized in that, Ceramic pig tail rings (4) are arranged in an equally spaced array on the side of the wire breakage protection mechanism (3).

3. The fully automatic chip transformer coil winding machine according to claim 2, characterized in that, The straightening and feeding mechanism (5) includes a wire straightening mechanism (6) located next to the wire breakage protection mechanism (3). The wire straightening mechanism (6) straightens the wire. A four-channel feeding mechanism (7) is located next to the wire straightening mechanism (6). A wire limit mechanism (8) is located next to the four-channel feeding mechanism (7).

4. The fully automatic chip transformer coil winding machine according to claim 1, characterized in that, The lower end of the guide frame (13) is fixedly connected to the base (15), the base (15) is fixedly connected to the frame (1), and the upper end of the base (15) is fixedly connected to the pneumatic push rod (14). When the pneumatic push rod (14) is started, it pushes the magnetic ring in the guide frame (13) to move to the upper end of the bearing rubber wheel (22).

5. The fully automatic chip transformer coil winding machine according to claim 4, characterized in that, A main motor (17) is fixedly connected to the frame (1) on the side of the guide frame (13), and a floating shaft (18) is keyed to the output end of the main motor (17). The floating shaft (18) is fixedly connected to a main gear (19) at the end away from the main motor (17). The main gear (19) is rotatably connected to the base (15). The main gear (19) is coaxially fixedly connected to a bearing rubber wheel (22).

6. The fully automatic chip transformer coil winding machine according to claim 5, characterized in that, A main side gear (20) is rotatably provided on the side of the main gear (19). The main side gear (20) is rotatably connected to the base (15) and meshes with the main gear (19). A secondary gear (21) is rotatably provided on the side of the main side gear (20). The secondary gear (21) is rotatably connected to the base (15) and meshes with the main side gear (20). The secondary gear (21) is coaxially fixed to another bearing rubber wheel (22).

7. The fully automatic chip transformer coil winding machine according to claim 4, characterized in that, A base (15) is provided with an adapter (24) on top of it. An auxiliary motor (25) is fixedly connected to the upper end of the adapter (24). The output end of the auxiliary motor (25) is set downward and fixedly connected to the main magnetic wheel (26). An auxiliary magnetic wheel (27) is provided at the lower end of the adapter (24). The main magnetic wheel (26) and the auxiliary magnetic wheel (27) are connected by magnetic transmission. The auxiliary magnetic wheel (27) is coaxially fixed to the assembly gear (28). The lower end of the assembly gear (28) is provided with a reversing gear (29) that is rotatably connected to the adapter (24). The reversing gear (29) meshes with the assembly gear (28). The lower end of the reversing gear (29) is provided with a limiting gear (30) that is rotatably connected to the adapter (24). The limiting gear (30) is coaxially fixed to the limiting rubber wheel (31).

8. The fully automatic chip transformer coil winding machine according to claim 7, characterized in that, A pneumatic swing arm (23) is provided on the side of the guide frame (13). The output end of the pneumatic swing arm (23) is fixedly connected to the adapter (24). When the pneumatic swing arm (23) is started, it drives the adapter (24) to move vertically.

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