A motor coil winding device and method

Abstract

The application 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, a pair of support plates are fixedly connected to the upper surface of the winding machine body, a self-adapting floating wire protection assembly is mounted on the outer surface of the support plates, a wire dynamic regulation and control assembly is mounted on the upper surface of the winding machine body, a fixing piece is mounted on the upper surface of the winding machine body, and a wire arranging quality sensing assembly is mounted on the upper surface of the winding machine body close to the fixing piece. The magnetorheological fluid in the magnetorheological fluid damper rapidly changes rheological characteristics under the action of real-time control of a magnetic field, effectively inhibits vibration transmission, avoids the phenomenon that wire breakage is caused by excessive tension, increases the resistance torque of a magnetic powder brake when the tension is monitored to be too small, slows down the rotating speed of a wire releasing disc to increase the tension, reduces the resistance torque of the magnetic powder brake when the tension is monitored to be too large, and accelerates wire releasing, so that the wire is always kept at an optimal traction angle.

Description

Technical Field

[0001] This invention relates to the field of motor manufacturing technology, and more specifically, to a motor coil winding device and method. Background Technology

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

[0003] In existing motor coil winding devices and methods, the motor stator workpiece to be wound is typically first installed and clamped onto the winding rod of the winding machine and fixed by a fixing mechanism. Then, the main shaft motor is started to drive the winding rod to rotate. At the same time, the wire laying mechanism works in coordination. The wire laying motor drives the linear slider and the wire laying nozzle mounting seat to make precise reciprocating motion along the axial direction of the winding rod through the ball screw and linear slide rail. This causes the wire laying nozzle to guide the wires to be inserted into the stator core slots in sequence according to the preset pitch, so as to achieve uniform wire arrangement and enable the coil winding work. This process continues until all the coils are wound. Then, the auxiliary fixing plate is released, the workpiece is removed, and the next work cycle begins.

[0004] In practical applications, existing technologies can easily lead to wire breakage or loosening due to excessive or insufficient tension during wire winding. Additionally, excessively tight or loose wiring can cause the coil to be squeezed and deformed or misaligned at the slot opening, affecting the uniformity of the motor's air gap and the stability of its power output. Therefore, it is necessary to provide a motor coil winding device and method to address the aforementioned technical problems. Summary of the Invention

[0005] The purpose of this invention is to provide a motor coil winding device and method to solve the above-mentioned problems.

[0006] To achieve the above objectives, an embodiment of the present invention provides the following technical solution:

[0007] A motor coil winding device and method includes a winding machine body, an adaptive floating wire protection component, a wire dynamic control component, and a wire quality sensing component. A pair of support plates are fixedly connected to the upper surface of the winding machine body. The adaptive floating wire protection component is installed on the outer surface of the support plates. The wire dynamic control component is installed on the upper surface of the winding machine body. A fixing member is installed on the upper surface of the winding machine body. The wire quality sensing component is installed on the upper surface of the winding machine body near the fixing member. The adaptive floating wire protection component includes a guide rail installed on the outer surface of the support plates. A floating plate is installed at the center of the inner cavity of one of the guide rails. Electric push rods are fixedly connected to the left and right sides of the floating plate. A slider is fixedly connected to one end of each of the two electric push rods. A connecting block is fixedly connected to the side of the slider. A floating rod is installed between the connecting blocks via a bearing seat.

[0008] The conductor dynamic control component includes a side plate mounted on the upper surface of the winding machine body. A bearing rod is mounted on the side of the side plate via a bearing, and a wire feeding reel is mounted on the outer surface of the bearing rod. The wire quality sensing component includes a wire feeding drive component mounted on the outer surface of the winding machine body. The wire feeding drive component includes a drive rod inserted through the outer surface of the winding machine body. A support base is mounted at one end of the drive rod. Two winding rods are mounted on the outer surface of the support base, and a sensing plate is mounted on the outer surface of the winding rods.

[0009] As a further improvement of the present invention, floating blocks are fixedly connected to the outer surfaces of the two support plates, and floating rods are connected between the two floating blocks through bearing seats. Guide rollers are installed on the outer surfaces of the two floating rods and the two floating rods. The outer surfaces of the guide rollers are coated with ceramic. A triangular guide path is formed by the guide rollers on the floating rods and the two floating rods. The three-point support effectively limits the lateral deviation of the conductor and prevents the conductor from derailing and jumping.

[0010] As a further improvement of the present invention, a miniature magnetorheological fluid damper is installed in the inner cavity of the two connecting blocks, and the slider is slidably connected to the inner cavity of the guide rail. The miniature magnetorheological fluid damper can sense and suppress vibrations caused by wire shaking in real time.

[0011] As a further improvement of the present invention, the outer surface of the pay-off reel is wound with a wire, and a magnetic powder brake is installed on the outer surface of the bearing rod near the pay-off reel. A three-dimensional force sensor is fixedly connected to the inner cavity of the magnetic powder brake. The three-dimensional force sensor detects the tension components of the wire in the X, Y, and Z directions in real time, thereby realizing a comprehensive perception of the pay-off tension.

[0012] As a further improvement of the present invention, a plurality of fixing blocks are fixedly connected to the outer surface of the support plate, and wire blocks are fixedly connected to the sides of each fixing block. The wire blocks can be stably installed on the support plate by means of the fixing blocks to ensure that their positions remain fixed.

[0013] As a further improvement of the present invention, the fixing component includes a fixing frame fixedly connected to the side of the support plate, two auxiliary fixing plates are installed on the lower surface of the fixing frame, multiple universal wheels are fixedly connected to the bottom of the winding machine body, and a door panel is rotatably connected to the outer surface of the winding machine body via a hinge. A handle is installed on the outer surface of the door panel. The motor stator can be fixed by the cooperation of the fixing frame and the auxiliary fixing plates to prevent the workpiece from loosening during the winding process.

[0014] As a further improvement of the present invention, a plurality of pressure sensors are fixedly connected to the upper surface of the sensing plate, and a silicone pad is installed on the outer surface of the pressure sensors. A base plate is fixedly connected to the upper surface of the support base, and a motor stator fixing block is installed on the upper surface of the base plate. An adjustment plate is installed on the outer surface of the winding rod near the upper surface of the silicone pad, and the motor stator is placed on the upper surface of the adjustment plate. The pressure sensors, in conjunction with the silicone pad, enable non-contact detection of the winding layer thickness and timely detection of winding abnormalities.

[0015] As a further improvement of the present invention, the cable drive includes a cable nozzle mounting seat fixedly mounted on the outer surface of the support plate. A cable nozzle is mounted on the side of the cable nozzle mounting seat. Both the cable nozzle and the inner cavity of the wire block are provided with wire channel holes. The cable nozzle mounting seat provides stable support for the cable nozzle, ensuring that it maintains a precise trajectory during reciprocating motion.

[0016] As a further improvement of the present invention, an inhibition ring is installed on the outer surface of the cable nozzle, a magnetorheological fluid chamber is installed in the inner cavity of the inhibition ring, an electromagnetic coil is installed on the outer surface of the magnetorheological fluid chamber, and the inner cavity of the magnetorheological fluid chamber is filled with magnetorheological fluid. When the vibration intensifies, the electromagnetic coil is energized to rapidly solidify the magnetorheological fluid, thereby increasing the stiffness of the inhibition ring and achieving active vibration suppression.

[0017] A winding method for a motor coil winding device includes the following steps:

[0018] S1. Place the motor stator to be wound on the adjustment plate and put it on the winding rod. Fix it with the fastener and motor stator fixing block. At the same time, pass the wire through the adaptive floating wire protection assembly in sequence and finally pre-wrap 1-2 turns on the surface of the motor stator to complete the wire path arrangement.

[0019] S2. Start the cable winding drive unit to drive the cable winding nozzle to reciprocate, thereby achieving precise winding of the motor stator.

[0020] S3. At the same time, the conductor dynamic control component detects the conductor tension and path deviation in real time, and adjusts the tension through the magnetic powder brake. The electric push rod drives the slider to move along the guide rail, which drives the guide roller to dynamically compensate for the conductor path deviation, ensuring the optimal traction angle and forming a closed-loop control of "detection-feedback-adjustment".

[0021] S4. The cable quality sensing component detects the winding status non-contactly through the pressure sensor on the sensing board. The main controller dynamically adjusts the cable parameters and tension based on the feedback signal to achieve real-time monitoring and closed-loop optimization of the winding quality.

[0022] Compared with the prior art, the advantages of this invention are:

[0023] (1) This scheme forms a stable triangular guide path through the cooperation of two floating rods, floating rod 1 and guide roller. The three-point support extends the wire wrap angle, enhances the stability of tension transmission, suppresses high-frequency vibration transmission, and effectively prevents the wire from jumping or derailing during high-speed operation. At the same time, the ceramic coating can prevent scratches on the wire surface and improve the stability and integrity of the winding process.

[0024] (2) When the tension of the conductor increases suddenly or high-frequency vibration occurs due to the sudden change in winding speed, the vibration is transmitted to the connecting block through the guide roller. The magnetorheological fluid inside the magnetorheological fluid damper changes its rheological properties rapidly under the action of the real-time control magnetic field, transforming from liquid to solid-like state, generating controllable damping force, effectively suppressing vibration transmission, and avoiding the phenomenon of conductor breakage due to excessive tension.

[0025] (3) Subsequently, the three-dimensional force sensor inside the pay-off reel detects the tension of the wire in real time, and the signal is transmitted synchronously to the magnetic powder brake on the bearing rod. When the tension is detected to be too low, the magnetic powder brake increases the resistance torque and slows down the speed of the pay-off reel to increase the tension. If the tension is too high, the magnetic powder brake decreases the resistance torque to speed up the pay-off. At the same time, the two electric push rods drive the slider to adjust the position of the two floating rods along the guide rail, dynamically compensating for the wire path deviation caused by the wire laying movement or mechanical error, ensuring that the wire is always at the optimal traction angle, thus forming a closed-loop control of "detection-feedback-adjustment", avoiding the wire winding deviation caused by the initial tension imbalance in the subsequent transmission, and ensuring that the wire enters the guide roller and wire laying stage with constant tension.

[0026] (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.

[0027] (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

[0028] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0029] Figure 2 This is a side view of the overall structure of the present invention;

[0030] Figure 3 This is a cross-sectional view of the overall structure of the present invention;

[0031] Figure 4 This is a partial structural cross-sectional view of the entire invention;

[0032] Figure 5 This is a cross-sectional view of the cable quality sensing component of the present invention;

[0033] Figure 6 This is a partial structural cross-sectional view of the sensing plate of the present invention;

[0034] Figure 7 This is a partial structural cross-sectional view of the cable nozzle of the present invention;

[0035] Figure 8 This is a partial structural cross-sectional view of the wire dynamic control component of the present invention;

[0036] Figure 9 For the present invention Figure 8 Enlarged view of the structure at point A in the middle;

[0037] Figure 10 For the present invention Figure 8 Enlarged view of the structure at point B.

[0038] Explanation of the labels in the diagram:

[0039] 1. Winding machine body; 101. Casters; 102. Door panel; 103. Support plate; 104. Fixing components; 1041. Fixing frame; 1042. Auxiliary fixing plate; 2. Adaptive floating conductor protection assembly; 202. Guide rail; 203. Slider; 204. Electric push rod; 205. Connecting block; 206. Floating rod one; 2061. Guide roller; 2062. Ceramic coating; 207. Miniature magnetorheological fluid damper; 208. Floating rod two; 209. Floating block; 3. Conductor dynamic control assembly; 301. Three-dimensional force sensor; 302. Pay-off reel; 303. Conductor; 30 4. Bearing rod; 305. Magnetic powder brake; 306. Side plate; 307. Suppression ring; 308. Magnetorheological fluid chamber; 309. Electromagnetic coil; 310. Conductor block; 4. Cable quality sensing component; 401. Sensing plate; 402. Pressure sensor; 403. Silicone pad; 404. Adjustment plate; 405. Base plate; 406. Cable drive component; 4061. Conductor channel hole; 4062. Cable nozzle; 4063. Cable nozzle mounting base; 4064. Motor stator; 4065. Winding rod; 4066. Support base; 4067. Drive rod; 4068. Motor stator fixing block. Detailed Implementation

[0040] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0041] Example 1:

[0042] Please see Figures 1-10 A motor coil winding device and method includes a winding machine body 1, a pair of support plates 103 fixedly connected to the upper surface of the winding machine body 1, and an adaptive floating wire protection component 2 installed on the outer surface of the support plates 103.

[0043] Specifically, the adaptive floating conductor protection assembly 2 includes a guide rail 202 mounted on the outer surface of the support plate 103. A floating plate is installed at the center of the inner cavity of one of the guide rails 202. Electric push rods 204 are fixedly connected to both sides of the floating plate. A slider 203 is fixedly connected to one end of each of the two electric push rods 204. The slider 203 is slidably connected to the inner cavity of the guide rail 202. 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 via a bearing seat. Floating blocks 209 are fixedly connected to the outer surfaces of the two support plates 103. A second floating rod 208 is connected via a bearing housing. Guide rollers 2061 are installed on the outer surfaces of the two first floating rods 206 and the second floating rod 208. The slider 203 is driven to move along the guide rail 202 by an electric push rod 204, which causes the first floating rod 206 and the guide rollers to move as a whole, realizing dynamic compensation of the path of the wire 303 and effectively adapting to the positional deviation during the wiring process. At the same time, the two guide rollers 2061 and the guide roller 2061 on the second floating rod 208 below together form a triangular guide path. The three-point support restricts the lateral vibration of the wire 303, improves the guiding stability, and prevents wire derailment and shaking.

[0044] The outer surface of the guide roller 2061 is coated with a ceramic coating 2062, which effectively prevents scratches on the surface of the wire 303. Miniature magnetorheological fluid dampers 207 are installed inside the cavities of the two connecting blocks 205. The outer shell of the miniature magnetorheological fluid damper 207 is made of magnetically conductive stainless steel, the interior is filled with carbonyl iron powder-based magnetorheological fluid, and an electromagnetic coil is wound around the exterior. When the wire 303 vibrates during high-speed winding or reversal, the vibration is transmitted to the connecting blocks 205 through the guide roller 2061 and the floating rod 206, thereby activating the sensor inside the miniature magnetorheological fluid damper 207, or directly causing magnetic... When the rheological fluid is subjected to shearing, the main controller applies current to the electromagnetic coil inside the fluid according to the vibration signal or a preset program, generating a controllable magnetic field. Under the action of the magnetic field, the magnetorheological fluid (containing carbonyl iron powder) filled in the miniature magnetorheological fluid damper 207 rapidly changes from a liquid state to a near-solid state, significantly increasing the shear yield strength and generating a controllable damping force, thereby suppressing vibration transmission and achieving millisecond-level active vibration reduction. When the vibration weakens, the controller cuts off or reduces the current, the magnetorheological fluid regains its fluidity, and the miniature magnetorheological fluid damper 207 enters a low-damping state, thereby achieving a dynamic response of the damping force and effectively reducing the risk of the conductor 303 being pulled and broken.

[0045] A wire dynamic control assembly 3 is installed on the upper surface of the winding machine body 1. The wire dynamic control assembly 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. Wire 303 is wound on the outer surface of the wire feeding reel 302. A magnetic powder brake 305 is installed on the outer surface of the bearing rod 304 near the wire feeding reel 302. A three-dimensional force sensor 301 is fixedly connected to the inner cavity of the magnetic powder brake 305. The three-dimensional force sensor 301 detects the tension components of the wire 303 in the X, Y, and Z directions in real time and feeds the signals back to the main controller to achieve accurate perception of the tension state. The magnetic powder brake 305 dynamically adjusts the output torque according to the feedback signal to control the rotation speed of the wire feeding reel 302, thereby maintaining a constant tension of the wire 303, forming a closed-loop tension control to ensure a stable and reliable winding process.

[0046] Multiple fixing blocks are fixedly connected to the outer surface of the support plate 103. Wire blocks 310 are fixedly connected to the sides of each fixing block. A fixing component 104 is installed on the upper surface of the winding machine body 1. 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. The fixing component 104 includes the fixing frame 1041, the auxiliary fixing plates 1042, and a driving element (such as a pneumatic cylinder or hydraulic cylinder). The output end of the driving element is connected to the auxiliary fixing plate 1042. During operation, the moving rod is driven downwards by hydraulic or pneumatic pressure, causing the auxiliary fixing plate 1042 to press vertically downwards, axially pressing the motor stator 4064 sleeved on the winding rod 4065. This prevents the workpiece from loosening or shifting due to rotational vibration during winding, ensuring winding accuracy and operational safety. The fixing component 104 is widely used in automated winding equipment and is a mature and reliable mechanical clamping device.

[0047] 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. A cable quality sensing component 4 is installed on the upper surface of the winding machine body 1 near the fixing member 104. The cable quality sensing component 4 includes a cable driving component 406 installed on the outer surface of the winding machine body 1. The cable 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.

[0048] A sensing plate 401 is mounted on the outer surface of the winding rod 4065. Multiple pressure sensors 402 are fixedly connected to the upper surface of the sensing plate 401, enabling non-contact real-time monitoring of the coil thickness and density during the winding process. A silicone pad 403 is mounted on the outer surface of each pressure sensor 402. The silicone pad 403 buffers and protects the pressure sensor 402 from damage by hard contact, while also effectively transmitting local pressure changes to ensure the sensitivity and accuracy of the detection signal. 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. The motor stator 4064 is placed on the upper surface of the adjusting plate 404. The distance between the sensing plate 401 and the motor stator 4064 on the adjusting plate 404 is between 1 and 3 mm, ensuring that the sensing plate 401 and the winding layer maintain a stable distance, so as to adapt to motor stators 4064 of different heights and specifications, improve detection consistency and system versatility.

[0049] The wire routing drive 406 includes a wire routing nozzle mounting base 4063 fixedly mounted on the outer surface of the support plate 103. A wire routing nozzle 4062 is mounted on the side of the wire routing nozzle mounting base 4063. Both the wire routing nozzle 4062 and the inner cavity of the wire block 310 are provided with wire channel holes 4061 to assist in guiding the wire routing. The wire routing drive 406 is a wire routing actuator widely used in precision winding equipment in the prior art. It mainly includes a wire routing motor, a ball screw, a linear slide rail and a linear slider assembly. The wire routing motor drives the ball screw to rotate, which drives the linear slider connected to it to make precise axial reciprocating motion along the linear slide rail, thereby driving the wire routing nozzle mounting base 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. The wire routing drive 406 can accurately control the wire routing displacement according to the preset pitch and speed parameters to ensure that the wire 303 is arranged in a single layer or multiple layers tightly, avoiding problems such as wire overlap and slot jumping.

[0050] An suppression ring 307 is installed on the outer surface of the cable guide 4062. The suppression ring 307 is made of a metal ring and a high-damping material (such as butyl rubber or polyurethane) pressed together. It can effectively suppress vibration and jitter caused by high-speed reciprocating motion during the cable laying process. A magnetorheological fluid chamber 308 is installed in the inner cavity of the suppression ring 307. An electromagnetic coil 309 is installed on the outer surface of the magnetorheological fluid chamber 308. The inner cavity of the magnetorheological fluid chamber 308 is filled with magnetorheological fluid. When the electromagnetic coil 309 is energized to generate a magnetic field, the magnetorheological fluid quickly changes from a liquid state to a near-solid state, which greatly improves the stiffness and damping performance of the suppression ring 307 and realizes active vibration control. Through the combination of "passive buffering + active adjustment", the micro-amplitude vibration of the cable guide 4062 is significantly reduced, ensuring that the wires 303 are arranged accurately and orderly, and avoiding defects such as wire overlap and slot skipping.

[0051] The winding machine body 1 is connected to an external AC socket via a power cable, and is supplied with 220V / 50Hz mains power. The power is converted to 24V DC power by an internal switching power supply to power various sensors, actuators and the main controller. The main controller is a PLC or an industrial embedded system, which is installed inside the winding machine body 1. It receives signals from the three-dimensional force sensor 301, pressure sensor 402, and wire position encoder, and outputs control commands to the magnetic powder brake 305, electric push rod 204, wire drive 406 and electromagnetic coil 309 to realize multi-variable collaborative closed-loop control.

[0052] Furthermore, the motor stator 4064 is fitted onto the winding rod 4065 and fixed by the fixing member 104. The wire 303 is led out from the wire feeding reel 302, passes through the guide roller 2061 in the adaptive floating wire protection assembly 2 in sequence, and is pre-wound 1-2 turns on the stator surface through the wire feeding nozzle 4062 to complete the path arrangement. During the winding process, the wire feeding drive member 406 drives the wire feeding nozzle 4062 to move precisely back and forth along the axial direction to achieve uniform wire feeding. When the wire 303 vibrates due to sudden speed change or reversal, the vibration is transmitted to the connecting block 205. Its built-in micro magnetorheological fluid damper 207 responds quickly under the command of the main controller. It controls the state of the magnetorheological fluid through the magnetic field, changing it from a liquid state to a near-solid state, generating a controllable damping force, effectively suppressing high-frequency vibration and reducing the risk of wire breakage.

[0053] Meanwhile, the three-dimensional force sensor 301 monitors the tension of the wire 303 in real time and feeds back the signal to the magnetic powder brake 305 to dynamically adjust the wire release resistance torque. The electric push rod 204 drives the slider 203 to move according to the control signal, which drives the guide roller 2061 to adjust its tension, forming a closed-loop tension of "detection-feedback-adjustment". Active vibration suppression can be achieved through the cooperation of the suppression ring 307 on the surface of the wire release nozzle 4062 and the magnetorheological fluid. The pressure sensor 402 on the sensing plate 401 detects the winding thickness and density non-contactly through the silicone pad 403. When an abnormality is detected, it immediately feeds back to the main controller to dynamically adjust the wire release parameters or adjust the tension in linkage, so as to realize online monitoring and closed-loop optimization of winding quality.

[0054] Working principle: During use, the winding machine body 1 is connected to an external power source via cables and sockets to ensure normal power supply. The operator places the motor stator 4064 to be wound on the adjusting plate 404 and places it on the winding rod 4065. The fixing component 104 is activated, which 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 feeding reel 302 and passes through the two guide rollers 2061, the floating block 209 and the wire channel hole 4061 of the wire feeding nozzle mounting seat 4063 in the adaptive floating wire protection component 2 in sequence, and finally leads out to the wire feeding nozzle 4062. It is pre-wound 1-2 turns on the surface of the motor stator 4064 to complete the arrangement of the wire 303 path. During this process, the wire 303 passes through the two guide rollers 2061 and then passes around the fixing roller below it to form a triangular guide path, which effectively limits the lateral deviation of the wire 303 and realizes anti-derailment guidance.

[0055] The wire guide nozzle 4062 is driven by the wire guide drive 406 to reciprocate along the axial direction via a ball screw and a linear guide rail, thereby achieving precise winding of the wire 303. When the winding speed of the wire 303 changes abruptly or the wire guide direction changes, resulting in high-frequency vibration, the vibration is transmitted to the connecting block 205 through the guide roller 2061. Under the command of the main controller, the micro magnetorheological fluid damper 207 integrated on its surface immediately adjusts the rheological properties of the internal magnetorheological fluid through an electromagnetic field, causing it to rapidly change from a liquid state to a near-solid state, generating a controllable damping force, effectively suppressing vibration transmission and reducing the risk of wire 303 being pulled and broken.

[0056] Meanwhile, the three-dimensional force sensor 301 inside the pay-off reel 302 detects the force state of the wire 303 in real time and transmits it synchronously to the magnetic powder brake 305 on the pay-off spindle, forming a closed-loop tension control system. When the detected tension is too low, the magnetic powder brake 305 increases the resistance torque and slows down the rotation speed of the pay-off reel 302 to increase the tension. If the tension is too high, the magnetic powder brake 305 decreases the resistance torque to speed up the pay-off. At the same time, the power supply and controller of the two electric push rods 204 are activated, so that the electric push rods 204 drive the sliders 203 to move along the guide rail 202, and drive the two floating rods 206 to move. This dynamically compensates for the deviation of the wire 303 path caused by the wire laying movement or mechanical error, ensuring that the wire 303 is always at the optimal traction angle. This forms a closed-loop control of "detection-feedback-adjustment", avoiding the winding deviation of the wire 303 caused by the initial tension imbalance in subsequent transmission.

[0057] When the cable nozzle 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 pressed together) absorbs low-amplitude vibrations through elastic deformation. If the vibration intensifies, the main controller immediately activates 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 and achieving active vibration suppression. Through the "passive + active" synergistic vibration suppression mechanism, the vibration of the cable nozzle 4062 is effectively reduced, ensuring the accurate arrangement of the wires 303 and avoiding problems such as wire overlap and slot skipping.

[0058] During the winding process of the motor stator 4064, the pressure sensor 402 in the sensing board 401 can detect the winding status in real time through non-contact pressure detection. When the winding is locally too thick, loose, or misaligned, the pressure sensor 402 at the corresponding position detects the abnormality and feeds it back to the main controller. The main controller will immediately adjust the motion parameters of the wire guide drive 406 or adjust the tension in linkage, realizing real-time monitoring and closed-loop optimization of winding quality, significantly improving the flatness and consistency of the winding, ensuring the uniformity of the motor air gap and the stability of electromagnetic performance, and greatly improving the product yield and the level of equipment intelligence.

[0059] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and not restrictive.

[0060] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style of the specification is merely for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

Claims

1. A motor coil winding apparatus, characterized by: Including the 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 provided with a self-adaptive floating wire protection assembly (2), the upper surface of the winding machine body (1) is provided with a wire dynamic regulation and control assembly (3), the upper surface of the winding machine body (1) is provided with a fixing piece (104), and the upper surface of the winding machine body (1) is provided with a wire quality sensing assembly (4) close to the fixing piece (104); The self-adaptive floating wire protection assembly (2) comprises a guide rail (202) mounted on the outer surface of the support plate (103), a floating plate is mounted in the inner cavity of one of the guide rails (202), and 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 side surface of the sliding block (203) is fixedly connected with a connecting block (205), and the connecting block (205) is installed between the bearings. The wire dynamic regulation and control assembly (3) comprises a side plate (306) mounted on the upper surface of the winding machine body (1), a bearing rod (304) is installed on the side surface of the side plate (306) through a bearing, and a pay-off disc (302) is installed on the outer surface of the bearing rod (304); The wire quality sensing assembly (4) comprises a wire driving piece (406) mounted on the outer surface of the winding machine body (1), the wire 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), the outer surface of the support base (4066) is provided with two winding rods (4065), and the outer surface of the winding rod (4065) is provided with a sensing plate (401).

2. A motor coil winding apparatus according to claim 1, wherein: The outer surfaces of the two support plates (103) are fixedly connected with floating blocks (209), the floating blocks (209) are connected through bearing seats, and the outer surfaces of the two floating rods (206) and the floating rods (208) are provided with guide rollers (2061).

3. A motor coil winding apparatus according to claim 1, wherein: The inner cavities of the two connecting blocks (205) are provided with micro magnetorheological fluid dampers (207), and the sliding blocks (203) and the inner cavities of the guide rails (202) are slidably connected.

4. The motor coil winding apparatus of claim 1, wherein: The outer surface of the pay-off disc (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 disc (302), and the inner cavity of the magnetic powder brake (305) is fixedly connected with a three-dimensional force sensor (301).

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 fixed blocks, and the side surfaces of the fixed blocks are fixedly connected with wire blocks (310).

6. A motor coil winding apparatus according to claim 1, wherein: The fixing part (104) includes a fixing frame (1041) fixedly connected to the side surface of the supporting plate (103), the lower surface of the fixing frame (1041) is provided with two auxiliary fixing plates (1042), 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 rotationally connected with a door plate (102) through a hinge, and the outer surface of the door plate (102) is provided with a handle.

7. A motor coil winding apparatus according to claim 1, wherein: The upper surface of the sensing plate (401) is fixedly connected with a plurality of pressure sensors (402), the outer surface of the pressure sensor (402) is provided with a silica gel pad (403), the upper surface of the supporting 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) is provided, close to the upper surface of the silica gel pad (403), with an adjusting plate (404), and the upper surface of the adjusting plate (404) is placed with a motor stator (4064).

8. A motor coil winding apparatus according to claim 5, wherein: The wire arranging driving part (406) includes a wire arranging nozzle mounting base (4063) fixedly mounted on the outer surface of the supporting plate (103), and the side surface of the wire arranging nozzle mounting base (4063) is provided with a wire arranging nozzle (4062), and the inner cavities of the wire arranging nozzle (4062) and the wire guide block (310) are both provided with wire guide channel holes (4061).

9. A motor coil winding apparatus according to claim 8, wherein: The outer surface of the wire arranging nozzle (4062) is provided with a suppression ring (307), the inner cavity of the suppression ring (307) is provided with a magnetorheological fluid chamber (308), the outer surface of the magnetorheological fluid chamber (308) is provided with an electromagnetic coil (309), and the inner cavity of the magnetorheological fluid chamber (308) is filled with magnetorheological fluid.

10. A method of winding a coil of an electric machine according to any one of claims 1-9, characterized in that: The method comprises the following steps: S1, placing the motor stator (4064) to be wound above the adjusting plate (404), sleeving the winding rod (4065), and fixing the motor stator (4064) through the fixing part (104) and the motor stator fixing block (4068), at the same time, the wire (303) is sequentially threaded through the self-adaptive floating wire protection assembly (2), and finally wound 1-2 turns on the surface of the motor stator (4064), and the wire path arrangement is completed; S2, starting the wire arranging driving part (406), driving the wire arranging nozzle (4062) to reciprocate, and realizing precise winding of the motor stator (4064); S3, at the same time, the wire dynamic control assembly (3) detects the wire (303) tension and path deviation in real time, adjusts the tension through the magnetic powder brake (305), drives the sliding block (203) to move along the guide rail (202) through the electric push rod (204), drives the guide roller (2061) to dynamically compensate the wire (303) path deviation, ensures that the traction angle is optimal, and forms a closed-loop control of "detection-feedback-regulation"; S4, the wire winding quality sensing assembly (4) non-contact detects the winding state through the pressure sensor (402) on the sensing plate (401), the main controller dynamically adjusts the winding parameters and tension according to the feedback signal, realizes real-time monitoring and closed-loop optimization of the winding quality.

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