Motor coil winding device and method

Abstract

The invention discloses a motor coil winding device and method, and belongs to the technical field of motor manufacturing, the motor coil winding device comprises a winding machine body, the upper surface of the winding machine body is fixedly connected with a pair of supporting plates, and the outer surfaces of the supporting plates are provided with self-adaptive floating wire protection assemblies; a wire dynamic regulation and control assembly is installed on the upper surface of the winding machine body, a fixing piece is installed on the upper surface of the winding machine body, and a winding displacement quality sensing assembly is installed on the portion, close to the fixing piece, of the upper surface of the winding machine body. The magnetorheological fluid in the magnetorheological fluid damper rapidly changes the rheological property under the action of a real-time control magnetic field, vibration transmission is effectively restrained, the phenomenon that a wire is broken due to too large tension is avoided, when it is monitored that the tension is too small, the magnetic powder brake increases the resisting moment and slows down the rotating speed of the pay-off reel to improve the tension, and if the tension is too large, the magnetic powder brake stops working. The magnetic powder brake reduces the resistance moment and accelerates the pay-off, and ensures that the wire is always at the optimal traction angle.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of motor manufacturing, more particularly, to a motor coil winding device and method. BACKGROUND

[0002] The motor coil winding device and method refers to a special device and its process flow for automatically winding the wire according to the set number of turns, pitch and winding path on the motor stator or rotor core. It is usually composed of a winding spindle, a wire arranging mechanism, a tension control system and a control system, etc. It can realize accurate arrangement of the wire and stable tension control, and is widely used in the production and manufacturing process of electromagnetic components such as motors, transformers and inductors. It is the key equipment to improve winding efficiency, consistency and product quality.

[0003] The existing motor coil winding device and method, when in use, usually first installs and clamps the motor stator workpiece to be wound on the winding rod of the winding machine, and fixes it through the fixing mechanism, then starts the spindle motor to drive the winding rod to rotate, and the wire arranging mechanism works cooperatively. The wire arranging motor drives the linear slide block and the wire arranging nozzle mounting seat to make precise reciprocating motion along the winding rod axis through the ball screw and the linear slide rail, so that the wire arranging nozzle guides the wire to be embedded into the stator core slot in turn according to the preset pitch, realizes uniform arrangement of the wire, and makes the coil winding work, until the whole coil winding is completed. Then the auxiliary fixing plate is loosened, the workpiece is taken down, and the next working cycle is carried out.

[0004] In actual use, the existing technology is prone to cause wire breakage or loosening due to excessive or insufficient tension during wire winding, and is prone to cause coil extrusion deformation or slot displacement at the slot opening due to tight or loose wire arrangement, which affects the uniformity of motor air gap and the stability of power output. Therefore, in view of the above technical problems, it is necessary to provide a motor coil winding device and method. SUMMARY

[0005] The present application relates to the technical field of motor manufacturing, more particularly, to a motor coil winding device and method.

[0006] In order to achieve the above-mentioned purpose, the technical scheme provided by an embodiment of the present application is as follows: The application discloses a motor coil winding device and method, which comprises a winding machine body, an adaptive floating wire protection assembly, a wire dynamic regulation assembly and a wire quality sensing assembly. The upper surface of the winding machine body is fixedly connected with a pair of support plates. The outer surface of the support plate is provided with the adaptive floating wire protection assembly. The upper surface of the winding machine body is provided with the wire dynamic regulation assembly. The upper surface of the winding machine body is provided with a fixing piece. The upper surface of the winding machine body is provided with the wire quality sensing assembly near the fixing piece. The adaptive floating wire protection assembly comprises guide rails installed on the outer surface of the support plate. The inner cavity of one of the guide rails is provided with a floating plate. The left and right sides of the floating plate are fixedly connected with electric push rods. The electric push rods are fixedly connected with sliding blocks at one end. The side surface of the sliding block is fixedly connected with a connecting block. The connecting block is provided with a floating rod one through a bearing seat.

[0007] The wire dynamic regulation assembly comprises a side plate installed on the upper surface of the winding machine body. The side surface of the side plate is provided with a bearing rod through a bearing. The outer surface of the bearing rod is provided with a wire unwinding disc. The wire quality sensing assembly comprises a wire driving piece installed on the outer surface of the winding machine body. The wire driving piece comprises a driving rod penetrating through the outer surface of the winding machine body. One end of the driving rod is provided with a support base. The outer surface of the support base is provided with two winding rods. The outer surface of the winding rod is provided with a sensing plate.

[0008] As a further improvement of the application, the outer surfaces of the two support plates are fixedly connected with floating blocks. The floating blocks are connected with a floating rod two through a bearing seat. The outer surfaces of the floating rod one and the floating rod two are provided with guide rollers. The outer surfaces of the guide rollers are provided with ceramic coatings. The guide rollers on the floating rod one and the floating rod two form a triangular guide path. The three-point support effectively limits the lateral deviation of the wire and prevents the wire from being off-wound and jumping.

[0009] As a further improvement of the application, the inner cavities of the two connecting blocks are provided with micro magnetorheological fluid dampers. The sliding blocks are slidingly connected with the inner cavities of the guide rails. The micro magnetorheological fluid dampers can sense and inhibit the vibration caused by the wire shaking in real time.

[0010] As a further improvement of the application, the outer surface of the wire unwinding disc is wound with a wire. The outer surface of the bearing rod is provided with a magnetic powder brake near the wire unwinding disc. The inner cavity of the magnetic powder brake is fixedly connected with a three-dimensional force sensor. The three-dimensional force sensor can detect the tension components of the wire in X, Y and Z directions in real time, so that the wire unwinding tension can be comprehensively sensed.

[0011] As a further improvement of the application, the outer surface of the support plate is fixedly connected with a plurality of fixing blocks, and the side surface of each fixing block is fixedly connected with a wire block.

[0012] As a further improvement of the application, the fixing member comprises a fixing frame fixedly connected to the side surface of the support plate, the lower surface of the fixing frame is provided with two auxiliary fixing plates, the bottom of the wire winding machine body is fixedly connected with a plurality of universal wheels, the outer surface of the wire winding machine body is hingedly connected with a door plate, and the outer surface of the door plate is provided with a handle.

[0013] As a further improvement of the application, the upper surface of the sensing plate is fixedly connected with a plurality of pressure sensors, the outer surface of the pressure sensor is provided with a silica gel pad, the upper surface of the support base is fixedly connected with a bottom plate, the upper surface of the bottom plate is provided with a motor stator fixing block, the outer surface of the wire winding rod is provided, close to the upper surface of the silica gel pad, with an adjusting plate, and the upper surface of the adjusting plate is placed with a motor stator.

[0014] As a further improvement of the application, the wire arranging driving member comprises a wire nozzle mounting seat fixedly mounted on the outer surface of the support plate, and the side surface of the wire nozzle mounting seat is provided with a wire nozzle.

[0015] As a further improvement of the application, the outer surface of the wire nozzle is provided with a suppression ring, the inner cavity of the suppression ring is provided with a magnetorheological fluid chamber, the outer surface of the magnetorheological fluid chamber is provided with an electromagnetic coil, and the inner cavity of the magnetorheological fluid chamber is filled with magnetorheological fluid.

[0016] A wire winding method of a motor coil winding device, comprising the following steps: S1, placing the motor stator to be wound above the adjusting plate, sleeving the motor stator on the wire winding rod, and fixing the motor stator through the fixing member and the motor stator fixing block, at the same time, threading the wire through the self-adaptive floating wire protection assembly, and finally winding 1-2 turns on the surface of the motor stator to complete the wire path arrangement; S2, starting the wire arranging driving member to drive the wire nozzle to reciprocate and realize precise winding of the motor stator; S3, meanwhile, the wire dynamic control assembly detects the wire tension and path deviation in real time, adjusts the tension through the magnetic powder brake, the electric push rod drives the sliding block to move along the guide rail, drives the guide roller to dynamically compensate the wire path deviation, ensures the optimal traction angle, and forms a closed loop control of "detection-feedback-regulation"; S4, the wire arrangement quality sensing assembly detects the winding state through the pressure sensor on the sensing plate, the main controller dynamically adjusts the wire arrangement parameters and tension according to the feedback signal, realizes real-time monitoring and closed-loop optimization of the winding quality.

[0017] Compared with the prior art, the advantages of the present application are: (1) the scheme forms a stable triangular guide path through the cooperation of the two floating rods and the guide roller, prolongs the wire wrap angle through three-point support, enhances the tension transmission stability, suppresses high-frequency vibration transmission, effectively prevents the wire from jumping or falling out of the groove during high-speed operation, and at the same time, the ceramic coating can prevent the wire surface from being scratched and improve the stability of the winding process and the wire integrity.

[0018] (2) when the wire tension suddenly increases or high-frequency vibration occurs due to sudden change of winding speed, the vibration is transmitted to the connecting block through the guide roller, the magnetorheological fluid in the magnetorheological fluid damper rapidly changes its rheological properties under the action of real-time control magnetic field, changes from liquid to solid-like state, generates controllable damping force, effectively suppresses vibration transmission, and avoids the phenomenon of wire breakage caused by excessive tension.

[0019] (3) subsequently, the three-dimensional force sensor inside the pay-off disc detects the wire tension in real time, the signal is transmitted to the magnetic powder brake on the bearing rod at the same time, when the monitored tension is too small, the magnetic powder brake increases the resistance torque, slows down the pay-off disc speed to increase the tension, if the tension is too large, the magnetic powder brake reduces the resistance torque to speed up the pay-off, at the same time, the two electric push rods drive the sliding blocks to adjust the positions of the two floating rods along the guide rails, dynamically compensate the wire path deviation caused by the wire arrangement movement or mechanical error, ensure that the wire is always at the optimal traction angle, thereby forming a closed loop control of "detection-feedback-regulation", avoiding the winding deviation caused by the initial tension imbalance in the subsequent transmission of the wire, and ensuring that the wire enters the guide roller and the wire arrangement link with constant tension.

[0020] (4) The suppression ring on the surface of the cable nozzle is made of a metal ring and a high-damping rubber layer (such as butyl rubber or polyurethane). The inner cavity is equipped with a magnetorheological fluid chamber and an electromagnetic coil is wound around it. When the cable nozzle vibrates due to high-speed reciprocating motion, the suppression ring first absorbs part of the high-frequency vibration through its own elastic deformation. If the vibration amplitude exceeds the rubber buffer range, the electromagnetic coil is energized to generate a magnetic field, which causes the magnetorheological fluid to quickly turn into a semi-solid state. The damping force is further enhanced to suppress the vibration. This synergistic effect of "passive rubber vibration reduction + active magnetorheological damping" effectively reduces the vibration amplitude of the cable nozzle, ensuring that the wire can be accurately laid along the wire channel hole of the cable nozzle, and avoiding the problems of wire stacking and slot jumping caused by vibration.

[0021] (5) Through the sensing plate and multiple pressure sensors, with the sensing plate located 1–3 mm below the winding, non-contact or light-contact pressure detection is achieved through the silicone pad. The silicone pad can prevent the pressure sensor from directly contacting the winding and causing damage, and can also effectively transmit local pressure signals. When the winding is locally too thick, loose, or the wire layer is offset, the pressure sensor at the corresponding position will detect the pressure abnormality and feed the signal back to the control system. The movement speed of the wire guide drive or the tension parameter is adjusted in a timely manner to achieve real-time monitoring and dynamic correction of the winding quality, ensuring the flatness and tightness of the motor stator winding, thereby realizing online sensing and closed-loop optimization of the winding forming quality, effectively avoiding coil extrusion deformation or slot misalignment, ensuring the uniformity of the motor air gap and the stability of electromagnetic performance, and significantly improving product yield and operational reliability. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a side view of the overall structure of the present invention; Figure 3 This is a cross-sectional view of the overall structure of the present invention; Figure 4 This is a partial structural cross-sectional view of the entire invention; Figure 5 This is a cross-sectional view of the cable quality sensing component of the present invention; Figure 6 This is a partial structural cross-sectional view of the sensing plate of the present invention; Figure 7 This is a partial structural cross-sectional view of the cable nozzle of the present invention; Figure 8 This is a partial structural cross-sectional view of the wire dynamic control component of the present invention; Figure 9 For the present invention Figure 8 Enlarged view of the structure at point A in the middle; Figure 10 For the present invention Figure 8 Enlarged view of the structure at point B.

[0023] Explanation of reference numerals in the figures: 1, winding machine body; 101, universal wheel; 102, door plate; 103, support plate; 104, fixing piece; 1041, fixing frame; 1042, auxiliary fixing plate; 2, self-adaptive floating wire protection assembly; 202, guide rail; 203, sliding block; 204, electric push rod; 205, connecting block; 206, floating rod one; 2061, guide roller; 2062, ceramic coating; 207, micro magneto-rheological fluid damper; 208, floating rod two; 209, floating block; 3, wire dynamic regulation assembly; 301, three-dimensional force sensor; 302, pay-off disc; 303, wire; 304, bearing rod; 305, magnetic powder brake; 306, side plate; 307, suppression ring; 308, magneto-rheological fluid chamber; 309, electromagnetic coil; 310, wire block; 4, wire arranging quality sensing assembly; 401, sensing plate; 402, pressure sensor; 403, silica gel pad; 404, adjusting plate; 405, bottom plate; 406, wire arranging driving piece; 4061, wire passage hole; 4062, wire arranging nozzle; 4063, wire arranging nozzle mounting seat; 4064, motor stator; 4065, winding rod; 4066, support base; 4067, driving rod; 4068, motor stator fixing block. DETAILED DESCRIPTION

[0024] The technical solutions of the present application will be described clearly and completely below in combination with the drawings of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0025] Embodiment 1: Please refer to Figures 1-10 A motor coil winding device and method, comprising a winding machine body 1, the upper surface of the winding machine body 1 is fixedly connected with a pair of support plates 103, the outer surface of the support plate 103 is installed with a self-adaptive floating wire protection assembly 2.

[0026] Specifically, the adaptive floating wire protection assembly 2 comprises guide rails 202 mounted on the outer surface of the support plates 103, the inner cavity of one of the guide rails 202 is centrally provided with a floating plate, the left and right sides of the floating plate are fixedly connected with electric push rods 204, one end of the two electric push rods 204 is fixedly connected with a sliding block 203, the sliding block 203 is slidingly connected with the inner cavity of the guide rail 202, the side surface of the sliding block 203 is fixedly connected with a connecting block 205, the connecting block 205 is provided with a floating rod one 206 through a bearing seat, the outer surfaces of the two support plates 103 are fixedly connected with floating blocks 209, the two floating blocks 209 are connected with a floating rod two 208 through a bearing seat, the outer surfaces of the two floating rod ones 206 and the floating rod two 208 are both provided with guide rollers 2061, the sliding block 203 is driven to move along the guide rail 202 by the electric push rod 204, the floating rod one 206 and the guide rollers are driven to displace as a whole, the dynamic compensation of the wire 303 path is realized, the position offset in the wire arranging process is effectively adapted, meanwhile, the two guide rollers 2061 and the guide rollers 2061 on the floating rod two 208 below jointly form a triangular guide path, the transverse vibration of the wire 303 is limited through three-point support, the guide stability is improved, and wire disconnection and shaking are prevented.

[0027] The outer surface of the guide roller 2061 is provided with a ceramic coating 2062, the ceramic coating 2062 can effectively prevent the surface of the wire 303 from being scratched, the inner cavities of the two connecting blocks 205 are provided with micro magnetorheological fluid dampers 207, the outer shell of the micro magnetorheological fluid damper 207 is magnetically conductive stainless steel, the inside is filled with carbonyl iron powder-based magnetorheological fluid, and the outside is wound with an electromagnetic coil, when the wire 303 vibrates in the high-speed winding or wire arranging reversing process, the vibration is transmitted to the connecting block 205 through the guide roller 2061 and the floating rod one 206, and then the sensor in the micro magnetorheological fluid damper 207 is excited, or the magnetorheological fluid is directly subjected to shearing action, the main controller applies current to the electromagnetic coil in the inside according to the vibration signal or a preset program, a controllable magnetic field is generated, under the action of the magnetic field, the magnetorheological fluid (containing carbonyl iron powder) filled in the micro magnetorheological fluid damper 207 rapidly changes from liquid state to quasi-solid state, the shearing yield strength is significantly improved, a controllable damping force is generated, thereby the vibration transmission is inhibited, and millisecond-level active vibration damping is realized, when the vibration is weakened, the controller cuts off or reduces the current, the magnetorheological fluid restores fluidity, and the micro magnetorheological fluid damper 207 enters a low-damping state, thereby the dynamic response of the damping force is realized, and the risk of wire 303 breakage is effectively reduced.

[0028] The upper surface of the winding machine body 1 is provided with a wire dynamic regulation and control assembly 3, the wire dynamic regulation and control assembly 3 comprises a side plate 306 installed on the upper surface of the winding machine body 1, the side surface of the side plate 306 is provided with a bearing rod 304 through a bearing, the outer surface of the bearing rod 304 is provided with a pay-off reel 302, the outer surface of the pay-off reel 302 is wound with a wire 303, the outer surface of the bearing rod 304 is provided with a magnetic powder brake 305 close to the pay-off reel 302, the inner cavity of the magnetic powder brake 305 is fixedly connected with a three-dimensional force sensor 301, the three-dimensional force sensor 301 is used to detect the tension components of the wire 303 in X, Y and Z directions in real time, and feedback signals to the main controller, so as to realize accurate perception of the tension state, and the magnetic powder brake 305 dynamically adjusts the output torque according to the feedback signals, controls the rotating speed of the pay-off reel 302, so as to maintain the constant tension of the wire 303, forms a closed-loop tension control, and ensures the stability and reliability of the winding process.

[0029] The outer surface of the support plate 103 is fixedly connected with a plurality of fixed blocks, the side surface of the fixed block is fixedly connected with a wire block 310, the upper surface of the winding machine body 1 is provided with a fixing piece 104, the fixing piece 104 comprises a fixing frame 1041 fixedly connected to the side surface of the support plate 103, the lower surface of the fixing frame 1041 is provided with two auxiliary fixing plates 1042, the fixing piece 104 comprises the fixing frame 1041, the auxiliary fixing plate 1042 and a driving element (such as a pneumatic cylinder or a hydraulic cylinder), the output end of the driving element is connected with the auxiliary fixing plate 1042, and in operation, the auxiliary fixing plate 1042 is vertically pressed downward through hydraulic or pneumatic driving of the moving rod, so as to axially press the motor stator 4064 sleeved on the winding rod 4065, prevent the workpiece from loosening or deviating due to rotating vibration in the winding process, ensure the winding precision and operation safety, and the fixing piece 104 has been widely applied in the automatic winding equipment and belongs to a mature and reliable mechanical clamping device.

[0030] The bottom of the winding machine body 1 is fixedly connected with a plurality of universal wheels 101, the outer surface of the winding machine body 1 is hingedly connected with a door plate 102, the outer surface of the door plate 102 is provided with a handle, the upper surface of the winding machine body 1 is provided with a wire arranging quality sensing assembly 4 close to the fixing piece 104, the wire arranging quality sensing assembly 4 comprises a wire arranging driving piece 406 installed on the outer surface of the winding machine body 1, the wire arranging driving piece 406 comprises a driving rod 4067 penetrating through the outer surface of the winding machine body 1, one end of the driving rod 4067 is provided with a support base 4066, and the outer surface of the support base 4066 is provided with two winding rods 4065.

[0031] The outer surface of the winding rod 4065 is provided with a sensing plate 401, the upper surface of the sensing plate 401 is fixedly connected with a plurality of pressure sensors 402, the non-contact real-time monitoring of the coil thickness and density during the winding process is realized, the outer surface of the pressure sensor 402 is provided with a silica gel pad 403, the silica gel pad 403 can not only buffer and protect the pressure sensor 402 from hard contact damage, but also can effectively transmit the local pressure change, so as to ensure the sensitivity and accuracy of the detection signal, the upper surface of the support base 4066 is fixedly connected with a bottom plate 405, the upper surface of the bottom plate 405 is provided with a motor stator fixing block 4068, the outer surface of the winding rod 4065 close to the upper surface of the silica gel pad 403 is provided with an adjusting plate 404, the upper surface of the adjusting plate 404 is placed with a motor stator 4064, the distance between the sensing plate 401 and the motor stator 4064 on the adjusting plate 404 is between 1-3mm, so as to ensure that the sensing plate 401 and the winding layer maintain a stable distance, so as to adapt to different height and specification of the motor stator 4064, and improve the detection consistency and system versatility.

[0032] The wire arranging driving part 406 includes a wire arranging nozzle mounting seat 4063 fixedly installed on the outer surface of the support plate 103, a wire arranging nozzle 4062 is installed on the side surface of the wire arranging nozzle mounting seat 4063, the wire arranging nozzle 4062 and the inner cavity of the wire guide block 310 are both provided with wire guide holes 4061, which are used for assisting in guiding the wire to move, the wire arranging driving part 406 is a wire arranging executing mechanism widely used in the prior art of precise winding equipment, mainly including a wire arranging motor, a ball screw, a linear slide rail and a linear slide block assembly, which drives the ball screw to rotate through the wire arranging motor, drives the linear slide block connected therewith to make precise axial reciprocating motion along the linear slide rail, and then drives the wire arranging nozzle mounting seat 4063 to move synchronously, so as to realize the uniform and orderly arrangement of the wire 303 in the winding slot of the motor stator 4064, and the wire arranging driving part 406 can accurately control the wire arranging displacement according to the preset pitch and speed parameters, so as to ensure that the wire 303 is closely arranged in single layer or multiple layers, and avoid problems such as wire stacking and slot skipping.

[0033] The outer surface of the wire arranging nozzle 4062 is provided with a suppression ring 307, the suppression ring 307 is formed by pressing a metal ring body and a high-damping material (such as butyl rubber or polyurethane), which can effectively suppress the vibration and shaking caused by high-speed reciprocating motion during the wire arranging process, the inner cavity of the suppression ring 307 is provided with a magneto-rheological fluid chamber 308, the outer surface of the magneto-rheological fluid chamber 308 is provided with an electromagnetic coil 309, and the inner cavity of the magneto-rheological fluid chamber 308 is filled with magneto-rheological fluid, when the electromagnetic coil 309 is powered to generate a magnetic field, the magneto-rheological fluid rapidly changes from liquid state to quasi-solid state, greatly improving the rigidity and damping performance of the suppression ring 307, realizing active vibration control, through the cooperation of “passive buffering + active adjustment”, the micro-vibration of the wire arranging nozzle 4062 is significantly reduced, the wire 303 is accurately and orderly arranged, and defects such as wire stacking and slot skipping are avoided.

[0034] The winding machine body 1 is connected with an external AC socket through a power cable, accesses 220V / 50Hz mains, and is converted into 24V DC by an internal switching power supply for use by various sensors, actuators, and main controllers. The main controller is a PLC or an industrial embedded system installed inside the winding machine body 1, receives signals from three-dimensional force sensors 301, pressure sensors 402, and wire arrangement position encoders, and outputs control instructions to magnetic powder brakes 305, electric push rods 204, wire arrangement driving members 406, and electromagnetic coils 309, achieving multi-variable collaborative closed-loop control.

[0035] Further, the motor stator 4064 is sleeved on the winding rod 4065 and fixed by the fixing member 104. The wire 303 is drawn out from the wire reel 302, passes through the guide roller 2061 in the adaptive floating wire protection assembly 2, and is pre-wound 1-2 turns on the surface of the stator through the wire arrangement nozzle 4062, completing the path arrangement. During the winding process, the wire arrangement driving member 406 drives the wire arrangement nozzle 4062 to move precisely and reciprocally along the axial direction, achieving uniform wire arrangement. When the wire 303 shakes due to sudden speed changes or direction changes, the vibration is transmitted to the connecting block 205, and the built-in micro magneto-rheological fluid damper 207 rapidly responds under the instruction of the main controller, changes the state of the magneto-rheological fluid from liquid to solid-like through magnetic field regulation, generates controllable damping force, effectively suppresses high-frequency vibration, and reduces the risk of wire breakage.

[0036] At the same time, the three-dimensional force sensor 301 monitors the tension of the wire 303 in real time, feeds back signals to the magnetic powder brake 305, dynamically adjusts the wire release resistance moment, and the electric push rod 204 drives the sliding block 203 to move according to the control signal, drives the guide roller 2061 to adjust the tension, forms a closed-loop tension of "detection-feedback-regulation", and actively suppresses vibration through the cooperation of the suppression ring 307 on the surface of the wire arrangement nozzle 4062 and the magneto-rheological fluid. The pressure sensor 402 on the sensing plate 401 detects the winding thickness and density through the silicone pad 403 without contact, feeds back to the main controller in real time when an abnormality is found, dynamically adjusts the wire arrangement parameters or linkage tension, and realizes online monitoring and closed-loop optimization of winding quality.

[0037] Working principle: in use, the winding machine body 1 is connected with external power supply through cable and socket, ensuring normal power supply, the staff places the motor stator 4064 to be wound on the adjusting plate 404 above and sets it on the winding rod 4065, starts the fixing part 104, drives the auxiliary fixing plate 1042 to move downward, so that the auxiliary fixing plate 1042 fixes the motor stator 4064, then the wire 303 is led out from the wire reel 302, passes through the two guide rollers 2061, the floating block 209 and the wire passage hole 4061 of the wire arranging nozzle mounting seat 4063 in the adaptive floating wire protection assembly 2 in sequence, is finally led out to the wire arranging nozzle 4062 and is pre-wound 1-2 turns on the surface of the motor stator 4064, completing the arrangement of the wire 303 path, in the process, the wire 303 passes through the two guide rollers 2061 and winds around the fixed roller below, forming a triangular guide path, effectively limiting the lateral deviation of the wire 303, realizing anti-offline guiding.

[0038] Then the wire arranging driving part 406 drives the wire arranging nozzle 4062 to reciprocate along the axial direction through the ball screw and the linear slide rail, realizing the precise arranging of the wire 303, when the wire 303 winding speed suddenly changes or the wire arranging reverses, high-frequency vibration is transmitted to the connecting block 205 through the guide roller 2061, the micro magnetorheological fluid damper 207 integrated on the surface of the connecting block 205 immediately adjusts the rheological property of the internal magnetorheological fluid through electromagnetic field under the instruction of the main controller, so that it rapidly changes from liquid state to solid-like state, generating controllable damping force, effectively inhibiting vibration transmission and reducing the risk of wire 303 breakage.

[0039] At the same time, the three-dimensional force sensor 301 in the wire reel 302 detects the stress state of the wire 303 in real time and synchronously transmits to the magnetic powder brake 305 on the wire reel main shaft, forming a closed-loop tension control system, when detecting that the tension is too small, the magnetic powder brake 305 increases the resistance torque to slow down the wire reel 302 speed to increase the tension, if the tension is too large, the magnetic powder brake 305 reduces the resistance torque to speed up the wire reel, while starting the power supply and controller of the two electric push rods 204, so that the electric push rods 204 drive the sliding blocks 203 to move along the guide rails 202 respectively, respectively driving the two floating rods 206 to move, dynamically compensating the deviation of the wire 303 path caused by wire arranging movement or mechanical error, ensuring that the wire 303 is always at the best traction angle, thereby forming a closed-loop control of "detection-feedback-regulation", avoiding the winding deviation of the wire 303 in subsequent transmission caused by initial tension imbalance.

[0040] When the wire outlet 4062 vibrates due to high-speed reciprocating motion, the suppression ring 307 on its surface (made of a metal ring and a high-damping rubber layer laminated together) will absorb low-amplitude vibrations through elastic deformation. If the vibration intensifies, the main controller will immediately activate the electromagnetic coil 309 to generate a magnetic field, causing the magnetorheological fluid in the magnetorheological fluid chamber 308 to rapidly thicken and solidify, significantly increasing the stiffness of the suppression ring 307, achieving active vibration suppression. Through the "passive + active" cooperative vibration suppression mechanism, the wire outlet 4062 is effectively reduced in vibration, ensuring accurate arrangement of the wires 303 and avoiding problems such as wire stacking and slot jumping.

[0041] When the motor stator 4064 is winding, the pressure sensor 402 in the sensing plate 401 can detect the winding condition in real time through non-contact pressure detection. When the winding is locally thick, loose or offset, the pressure sensor 402 at the corresponding position detects the abnormality and feeds back to the main controller. The main controller will immediately adjust the motion parameters of the wire arrangement driving member 406 or link to adjust the tension, realizing real-time monitoring and closed-loop optimization of winding quality, significantly improving winding flatness and consistency, ensuring uniformity of motor air gap and stability of electromagnetic performance, and greatly improving product yield and equipment intelligence level.

[0042] It is obvious to those skilled in the art that the present application is not limited to the details of the above exemplary embodiments, and can be implemented in other specific forms without departing from the spirit or essential characteristics of the present application. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting.

[0043] In addition, it should be understood that although the present specification is described in terms of embodiments, each embodiment does not contain only one independent technical solution. The description of the specification is only for the sake of clarity, and those skilled in the art should consider the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that those skilled in the art can understand.

Claims

1. A motor coil winding apparatus, characterized by: The device includes a winding machine body (1), a pair of support plates (103) are fixedly connected to the upper surface of the winding machine body (1), an adaptive floating wire protection component (2) is installed on the outer surface of the support plate (103), a wire dynamic control component (3) is installed on the upper surface of the winding machine body (1), a fixing component (104) is installed on the upper surface of the winding machine body (1), and a wire quality sensing component (4) is installed on the upper surface of the winding machine body (1) near the fixing component (104). The adaptive floating conductor protection assembly (2) includes a guide rail (202) installed on the outer surface of the support plate (103). A floating plate is installed in the center of the inner cavity of one of the guide rails (202). Electric push rods (204) are fixedly connected to the left and right sides of the floating plate. A slider (203) is fixedly connected to one end of the two electric push rods (204). A connecting block (205) is fixedly connected to the side of the slider (203). A floating rod (206) is installed between the connecting blocks (205) through a bearing seat. The conductor dynamic control component (3) includes a side plate (306) installed on the upper surface of the winding machine body (1). A bearing rod (304) is installed on the side of the side plate (306) via a bearing. A wire feeding reel (302) is installed on the outer surface of the bearing rod (304). The wire quality sensing component (4) includes a wire driving component (406) installed on the outer surface of the winding machine body (1). The wire driving component (406) includes a driving rod (4067) inserted through the outer surface of the winding machine body (1). A support base (4066) is installed at one end of the driving rod (4067). Two winding rods (4065) are installed on the outer surface of the support base (4066). A sensing plate (401) is installed on the outer surface of the winding rods (4065).

2. A motor coil winding apparatus according to claim 1, wherein: A floating block (209) is fixedly connected to the outer surface of the two support plates (103). A floating rod (208) is connected between the two floating blocks (209) through a bearing seat. A guide roller (2061) is installed on the outer surface of the two floating rods (206) and the two floating rods (208). A ceramic coating (2062) is installed on the outer surface of the guide roller (2061).

3. A motor coil winding apparatus according to claim 1, wherein: The inner cavities of two of the connecting blocks (205) are equipped with miniature magnetorheological fluid dampers (207), and the slider (203) is slidably connected to the inner cavity of the guide rail (202).

4. The motor coil winding apparatus of claim 1, wherein: The outer surface of the pay-off reel (302) is wound with wire (303), and a magnetic powder brake (305) is installed on the outer surface of the bearing rod (304) near the pay-off reel (302). A three-dimensional force sensor (301) is fixedly connected to the inner cavity of the magnetic powder brake (305).

5. A motor coil winding apparatus according to claim 1, wherein: The outer surface of the support plate (103) is fixedly connected with a plurality of fixing blocks, and each fixing block is fixedly connected with a wire block (310) on its side.

6. A motor coil winding apparatus according to claim 1, wherein: The fixing component (104) includes a fixing frame (1041) fixedly connected to the side of the support plate (103). Two auxiliary fixing plates (1042) are installed on the lower surface of the fixing frame (1041). Multiple casters (101) are fixedly connected to the bottom of the winding machine body (1). A door panel (102) is rotatably connected to the outer surface of the winding machine body (1) via a hinge. A handle is installed on the outer surface of the door panel (102).

7. The motor coil winding device according to claim 1, characterized in that: Multiple pressure sensors (402) are fixedly connected to the upper surface of the sensing plate (401). A silicone pad (403) is installed on the outer surface of the pressure sensor (402). A base plate (405) is fixedly connected to the upper surface of the support base (4066). A motor stator fixing block (4068) is installed on the upper surface of the base plate (405). An adjusting plate (404) is installed on the outer surface of the winding rod (4065) near the upper surface of the silicone pad (403). A motor stator (4064) is placed on the upper surface of the adjusting plate (404).

8. A motor coil winding device according to claim 5, characterized in that: The cable drive component (406) includes a cable nozzle mounting base (4063) fixedly installed on the outer surface of the support plate (103). A cable nozzle (4062) is installed on the side of the cable nozzle mounting base (4063). Both the cable nozzle (4062) and the inner cavity of the wire block (310) are provided with wire channel holes (4061).

9. A motor coil winding device according to claim 8, characterized in that: An inhibition ring (307) is installed on the outer surface of the cable nozzle (4062), a magnetorheological fluid chamber (308) is installed in the inner cavity of the inhibition ring (307), an electromagnetic coil (309) is installed on the outer surface of the magnetorheological fluid chamber (308), and the inner cavity of the magnetorheological fluid chamber (308) is filled with magnetorheological fluid.

10. A winding method for a motor coil winding device according to any one of claims 1-9, characterized in that: Includes the following steps: S1. Place the motor stator (4064) to be wound on the adjustment plate (404) and put it on the winding rod (4065). Fix it with the fastener (104) and the motor stator fixing block (4068). At the same time, pass the wire (303) through the adaptive floating wire protection assembly (2) in sequence, and finally pre-wrap 1-2 turns on the surface of the motor stator (4064) to complete the wire path arrangement. S2. Start the cable routing drive (406) to drive the cable routing nozzle (4062) to reciprocate, thereby achieving precise winding of the motor stator (4064); S3. At the same time, the conductor dynamic control component (3) detects the tension and path deviation of the conductor (303) in real time, and adjusts the tension through the magnetic powder brake (305). The electric push rod (204) drives the slider (203) to move along the guide rail (202), which drives the guide roller (2061) to dynamically compensate for the path deviation of the conductor (303) to ensure the optimal traction angle and form a closed-loop control of "detection-feedback-adjustment". S4. The wiring quality sensing component (4) detects the winding status non-contactly through the pressure sensor (402) on the sensing board (401). The main controller dynamically adjusts the wiring parameters and tension according to the feedback signal to realize real-time monitoring and closed-loop optimization of the winding quality.

Images