A transformer coil foil winder

Abstract

The application provides a transformer coil foil winding machine, and relates to the technical field of transformer production. The foil winding machine comprises a rolling frame body, a guiding support frame body, a foil release frame body and a winding mechanism. The foil release frame body is provided with double release wheels for winding foil pieces and insulating spacers. The winding mechanism comprises a rolling shaft and an alignment structure. The rolling shaft is connected to a rolling motor and is provided with a slidable rolling core. The two ends of the core are provided with sliding supports. The alignment structure controls the movement of two centering clamping units towards each other through a synchronous driving unit, and the sliding supports are clamped in a rolling contact mode, so that the core is automatically centered and dynamically stabilized. During rolling, the centering clamping unit limits the vibration of the core, and ensures the accurate lamination of the foil and the insulating spacers. After completion, the clamping unit is reset to a horizontal state, which facilitates the quick replacement of the core. The application solves the problems of misalignment, wrinkles and low efficiency of the traditional winding machine, and significantly improves the electrical conductivity, heat dissipation and production efficiency of the transformer coil.

Description

Technical Field

[0001] This invention relates to the field of transformer manufacturing technology, and in particular to a transformer coil foil winding machine. Background Technology

[0002] A transformer consists of an iron core (or magnetic core) and coils. The coils have two or more windings; the winding connected to the power source is called the primary winding, and the others are called secondary windings. It can transform AC voltage, current, and impedance. As a key piece of equipment in a power system, the performance of the transformer directly affects the efficiency and stability of power transmission. Traditional transformers mostly use wire-wound coils, which suffer from low conductivity, poor heat dissipation, and insufficient mechanical strength. In recent years, foil coils have gradually become the mainstream choice for transformer windings due to their large conductive cross-sectional area, low eddy current losses, and excellent heat dissipation performance.

[0003] However, the winding process for foil coils requires extremely high precision, ensuring accurate alignment of the copper foil and insulating spacers, and tight bonding between layers. Otherwise, misalignment, wrinkles, and other problems can easily occur, affecting product performance. Existing winding equipment often suffers from insufficient positioning accuracy, core vibration during winding, and low replacement efficiency, making it difficult to meet the production requirements of high-quality foil coils. Summary of the Invention

[0004] The purpose of this invention is to provide a transformer coil foil winding machine to solve the technical problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A transformer coil foil winding machine includes a winding frame, a guide support frame, a foil release frame, and a winding mechanism. The winding frame and the guide support frame are arranged opposite to each other. The foil release frame is mounted on the guide support frame and has two release wheels, which respectively wind foil sheets and insulating spacers. The guide support frame is also provided with two guide rollers that respectively guide the foil sheets and insulating spacers. The winding mechanism is mounted on the winding frame and includes a winding shaft and an alignment structure. One end of the winding shaft is rotatably connected to the winding frame and connected to a winding motor. The winding shaft has a function for feeding the foil sheets... The core is a rolled core on which the sheet and insulating spacer are wound together. The rolled core can slide on the core and has sliding supports at both ends. The alignment structure includes a synchronous drive unit and two centering clamping units. The two centering clamping units are arranged opposite each other and one end is connected to the synchronous drive unit. The centering clamping units can rotate around the connection point with the synchronous drive unit. The end of the centering clamping unit away from the synchronous drive unit can be locked onto the sliding support from one side in a rolling contact manner. The synchronous drive unit is provided on the rolling frame and is used to drive the two centering clamping units to move synchronously in opposite directions along the axis of the rolling shaft.

[0007] Based on the above technical solutions, the present invention also provides the following optional technical solutions:

[0008] In one alternative embodiment: the synchronous drive unit includes left and right spiral lead screws, an alignment motor, and a limiting assembly. The left and right spiral lead screws are rotatably mounted on the winding frame and connected to the output end of the alignment motor mounted on the winding frame, with their axes parallel to the axis of the winding shaft. Both ends of the left and right spiral lead screws are provided with spiral sleeves that engage with them. The ends of the two centering clamping units are rotatably connected to the two spiral sleeves respectively. The limiting assembly is mounted on the winding frame and connected to both spiral sleeves. The limiting assembly can restrict the spiral sleeves from rotating relative to the center of the left and right spiral lead screws. The winding frame is also provided with two rotating action parts, and the ends of the centering clamping units near the spiral sleeves are connected to the corresponding rotating action parts. The rotating action parts can drive the centering clamping units in a moving state to rotate around the spiral sleeves.

[0009] In one alternative embodiment: the rotating part is a push plate, one end of the rotating part is curved and the other end remains parallel to the axis of the left and right screw rods, the centering clamping unit includes a clamping arm and an abutting clamping block, one end of the clamping arm is provided with a connecting sleeve and a lower extension roller, the connecting sleeve is rotatably mounted on the corresponding spiral sleeve through an elastic damping bearing, the lower extension roller is rotatably engaged with the side of the clamping arm and abuts against the end face of the rotating part, the abutting clamping block is provided at the end of the clamping arm away from the connecting sleeve, and the inner wall of the abutting clamping block can roll against the circumferential surface of the sliding support.

[0010] In one alternative: the abutting clamping block is semi-circular in shape and the inner wall of the abutting clamping block has a plurality of equally spaced movable balls; the sliding support includes a support sleeve, a connecting flange and a pressure-bearing rotating ring, the support sleeve is slidably sleeved on the rolling shaft, the connecting flange is located at one end of the support sleeve and can be fastened to the end face of the rolled core by bolts, and the pressure-bearing rotating ring is rotatably mounted on the support sleeve with a gap between the pressure-bearing rotating ring and the rolled core.

[0011] In one alternative embodiment: the limiting assembly includes a fixed guide post, a movable sleeve, and two limiting links. The fixed guide post is fixed on the rolling frame and positioned opposite the release wheel. The top of the fixed guide post has a top plate. The movable sleeve slides on the fixed guide post and is connected to the top plate by an anti-slip spring. The two limiting links are located on both sides of the two fixed guide posts. One end of each limiting link is hinged to a limiting fixed sleeve, which is fixedly fitted onto a corresponding spiral sleeve. The other end of the limiting link is connected to the outer wall of the movable sleeve.

[0012] In one alternative embodiment: the top of the guide support frame is further provided with a rolling and compacting assembly, which includes an upper frame, an adjusting shaft, an adjusting motor, and a rolling and rolling unit. The adjusting shaft is rotatably mounted on the guide support frame and one end of it is connected to the output end of the adjusting motor. One end of the upper frame is connected to the upper frame and the other end can extend to the upper side of the rolling shaft. The rolling and rolling unit is vertically movable on the upper frame, and the lower end of the rolling and rolling unit can abut against the outer surface of the rolled core in a rolling contact manner and apply elastic pressure.

[0013] In one alternative: the top of the guide support frame is further provided with a blocking plate. The blocking plate is located on the lower side of the upper frame near the adjusting shaft and is fixedly connected to the top of the guide support frame through a fixed side rod. The surface of the blocking plate has a magnet. When the rolling and pressing unit is directly above the rolling core, the upper frame and the surface of the blocking plate are in contact and the two are magnetically attracted to each other.

[0014] In one alternative embodiment: the rolling and pressing unit includes a rolling main frame and two rolling wheels. The upper surface of the rolling main frame is provided with at least one movable guide post. The movable guide post can slide through the upper frame and has a movable plate at its top. The movable plate is connected to the upper surface of the upper frame by a downward pressure spring. Movable shafts are provided on both sides of the rolling main frame. Each movable shaft is connected to a movable rolling rod frame by an elastic damping bearing. The end of the movable rolling rod frame away from the movable shaft is provided with a freely rotatable rolling wheel. The surface of the rolling wheel has a rubber layer.

[0015] In one alternative embodiment: the guide support frame is further provided with a tension adjustment assembly located between the guide support frame and the winding frame. The tension adjustment assembly includes two tension frames, which are arranged opposite each other and each is provided with a tension adjustment shaft. The tension adjustment shaft is rotatably connected to the guide support frame via an elastic damping bearing. Two tension rollers are provided between the two tension adjustment shafts. The ends of the tension rollers are rotatably engaged with the tension frames. The foil sheet and the insulating spacer both pass through the space between the two tension rollers. A tension adjustment gear is provided on the tension adjustment shaft. The upper frame is also provided with a vertically movable connecting rod, and the bottom of the connecting rod is provided with a tension adjustment rack that can mesh with the tension adjustment gear. An extension connecting rod connected to the top of the connecting rod is provided on the movable plate.

[0016] By adopting the above technical solution, the present invention has the following beneficial effects:

[0017] In the transformer coil foil winding machine provided by this invention, two centering clamping units are controlled by a synchronous drive unit to move towards each other, pushing the winding core from both ends to be strictly aligned with the release wheel. This ensures that there is no misalignment or wrinkles when the foil and insulating sheet are wound, forming a multi-layered, precisely stacked coil structure. The centering clamping unit continuously presses against the sliding support in a rolling contact manner, which not only limits the axial vibration of the winding core and ensures the neatness between layers, but also does not hinder the rotation of the core, improving the winding quality and efficiency. After winding is completed, the centering clamping unit automatically resets to a horizontal state and moves away from the winding shaft, facilitating the quick removal of the finished coil and replacement of the new core, significantly shortening downtime and adapting to the needs of mass production. The guide roller and the release wheel work together to realize the synchronous conveying of the foil and insulating sheet. The integrated design of the winding motor drive and alignment structure simplifies the operation process, reduces manual intervention, and is suitable for the automated production of high-precision transformer coils. Attached Figure Description

[0018] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the overall structure of a foil winding machine according to one embodiment of the present invention.

[0020] Figure 2 This is a schematic diagram of the winding mechanism structure in one embodiment of the present invention.

[0021] Figure 3 This is a schematic diagram of the alignment structure in one embodiment of the present invention.

[0022] Figure 4 This is a schematic diagram of the centering clamping unit structure in one embodiment of the present invention.

[0023] Figure 5 This is a schematic diagram of the rolling and compaction assembly structure in one embodiment of the present invention.

[0024] Figure 6 This is a schematic diagram of the rolling and pressing unit structure in one embodiment of the present invention.

[0025] Reference numerals in the attached drawings: 100, winding frame; 200, guide support frame; 210, guide roller; 300, foil release frame; 310, foil sheet; 320, insulating spacer; 400, winding core; 410, sliding support; 411, support sleeve; 412, connecting flange; 413, pressure-bearing rotating ring; 500, winding shaft; 510, winding motor; 600, left and right spiral screw; 610, spiral sleeve; 611, alignment motor; 620, centering clamping unit; 630, clamping arm; 631, connecting rotating sleeve; 633, abutting clamping block; 634, movable ball bearing; 635, lower extension roller; 640, limiting assembly; 641, fixed guide post; 642, movable sleeve. Limited connecting rod 643, limited fixing sleeve 644, anti-slip spring 645, rotating action part 650, rolling and compacting assembly 700, upper frame 710, adjusting rotating shaft 720, adjusting motor 730, rolling and rolling unit 740, rolling main frame 741, movable shaft 742, movable rolling rod frame 743, rolling wheel 744, movable guide post 745, movable plate 746, downward pressure spring 747, extension connecting rod 748, blocking plate 750, fixed side rod 760, connecting movable rod 770, tension adjustment assembly 800, tension frame 810, tension roller 820, tension adjustment rotating shaft 830, tension adjustment gear 840, tension adjustment rack 850. Detailed Implementation

[0026] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] The left, right, up, and down positions of the various components shown in the attached diagram are just one arrangement method; the specific positions should be set according to specific needs.

[0028] In one embodiment, such as Figures 1-3As shown, a transformer coil foil winding machine includes a winding frame 100, a guide support frame 200, a foil release frame 300, and a winding mechanism. The winding frame 100 and the guide support frame 200 are arranged opposite to each other. The foil release frame 300 is mounted on the guide support frame 200 and has two release wheels, which respectively wind foil sheet 310 and insulating spacer 320. The guide support frame 200 is also provided with two guide rollers 210 that respectively guide the foil sheet 310 and the insulating spacer 320. The winding mechanism is mounted on the winding frame 100 and includes a winding shaft 500 and an alignment structure 600. One end of the winding shaft 500 is rotatably connected to the winding frame 100 and connected to a winding motor 510. The rotating shaft 500 has a rolled core 400 for winding the foil sheet 310 and the insulating spacer 320 together. The rolled core 400 can slide on it, and both ends of the rolled core 400 have sliding supports 410. The alignment structure 600 includes a synchronous drive unit and two centering clamping units 630. The two centering clamping units 630 are arranged opposite each other and one end is connected to the synchronous drive unit. The centering clamping unit 630 can rotate about its connection with the synchronous drive unit. The end of the centering clamping unit 630 away from the synchronous drive unit can be locked onto the sliding support 410 from one side in a rolling contact manner. The synchronous drive unit is provided on the rolling frame 100 and is used to drive the two centering clamping units 630 to move synchronously in opposite directions along the axis of the rolling rotating shaft 500.

[0029] In this embodiment of the invention, initially, the two centering clamping units 630 are horizontal and located at both ends of the winding frame 100; the winding core 400 and its sliding supports 410 at both ends can be placed on the winding rotating shaft 500 from one end and pushed to the middle position of the winding rotating shaft 500; the synchronous drive unit starts working and drives the two centering clamping units 630 to move synchronously and towards each other, and the centering clamping units 630 also rotate around the synchronous drive unit while moving. The moving unit rotates until the end of the centering clamping unit 630 away from the synchronous drive unit can abut against the sliding support 410; the two centering clamping units 630 move towards each other and act on the winding core 400 from both ends, so that the winding core 400 moves to a position opposite to the release wheel, which can ensure accurate alignment and avoid misalignment and wrinkles caused by misalignment during copper foil winding; the ends of the foil sheet 310 and the insulating spacer 320 away from the release wheel pass through the two guide rollers 210 respectively, and are wound... The outer surfaces of the core 400 are fixed together; the winding motor 510 operates and drives the winding shaft 500 to rotate, which in turn drives the winding core 400 and the sliding support 410 to rotate, allowing the foil sheet 310 and the insulating spacer 320 to be simultaneously wound onto the winding core 400 to form a multi-layered, precisely stacked foil coil, replacing the traditional wire-wound coil and improving the transformer's conductivity, heat dissipation, and mechanical strength; during the winding process, the two centering clamping units 630 always abut against the two The sliding support 410 is positioned on the side to limit the vibration of the wound core 400 on the winding shaft 500, ensuring the neatness of each layer of foil coil. Since the centering clamping unit 630 and the outer wall of the sliding support 410 are in rolling contact, the centering clamping unit 630 will not obstruct the rotation of the wound core 400, thus ensuring the orderly winding process. After the foil coil wound on the wound core 400 reaches a certain length, it is cut using a cutting device (which can be installed on the guide support frame 200 or cut manually). After the end of the foil coil is cut, the synchronous drive unit starts working again and drives the two centering clamping units 630 to move to both ends of the winding frame 100 respectively. The centering clamping units 630 no longer restrict the winding core 400 from both ends, and the centering clamping units 630 also rotate around their connection with the synchronous drive unit. The centering clamping units 630 gradually move away from the winding shaft 500 and rotate to a horizontal state. The centering clamping units 630 will not block the winding core 400 from sliding out from one end of the winding shaft 500, so that the winding core 400 can be quickly replaced and the winding efficiency can be improved.

[0030] In one embodiment, such as Figures 1-3As shown, the synchronous drive unit includes left and right spiral lead screws 610, an alignment motor 620, and a limiting assembly 640. The left and right spiral lead screws 610 are rotatably mounted on the winding frame 100 and connected to the output end of the alignment motor 620 mounted on the winding frame 100. Their axis is parallel to the axis of the winding shaft 500. Both ends of the left and right spiral lead screws 610 are provided with spiral sleeves 611 that engage with them. The ends of two centering clamping units 630 are rotatably connected to the two spiral sleeves 611 respectively. The limiting assembly 640 is mounted on the winding frame 100 and connected to both spiral sleeves 611. The limiting assembly 640 can restrict the spiral sleeves 611 from rotating relative to the center of the left and right spiral lead screws 610. The winding frame 100 also has two rotating action parts 650, and the end of the centering clamping unit 630 near the spiral sleeve 611 is connected to the corresponding rotating action part 650. The rotating action part 650 can... The centering clamping unit 630, which is in a moving state, rotates around the spiral sleeve 611. In this embodiment of the invention, the alignment motor 620 works and drives the left and right spiral screws 610 to rotate. The spiral sleeve 611, through its spiral engagement with the two spiral sleeves 611 and the limiting component 640 restricting the rotation of the two spiral sleeves 611, allows the two spiral sleeves 611 to move synchronously in opposite directions along the axis of the left and right spiral screws 610. The centering clamping unit 630 moves with the corresponding spiral sleeve 611 and rotates relative to the spiral sleeve 611 under the action of the rotating action part 650. The end of the centering clamping unit 630 away from the spiral sleeve 611 can roll and lock onto the sliding support 410 and push the sliding support 410, so that the wound core 400 can move on the winding shaft 500 to a position aligned with the release wheel, or move towards both ends of the winding frame 100 so that the centering clamping unit 630 moves away from the sliding support 410, allowing for quick replacement of the wound core 400.

[0031] In one embodiment, such as Figures 1-3As shown, the rotating part 650 is a top plate. One end of the rotating part 650 is curved, and the other end remains parallel to the axis of the left and right spiral screw 610. The centering clamping unit 630 includes a clamping arm 631 and an abutting clamping block 633. One end of the clamping arm 631 is provided with a connecting rotating sleeve 632 and a lower extension roller 635. The connecting rotating sleeve 632 is rotatably mounted on the corresponding spiral sleeve 611 through an elastic damping bearing. The lower extension roller 635 and the clamping arm 631 are connected by a connecting rotating sleeve 632 and a lower extension roller 635. 31 The side rotational engagement and the lower extension roller 635 abut against the end face of the rotating action part 650. The abutment clamping block 633 is provided at the end of the clamping support arm 631 away from the connecting rotating sleeve 632. The inner wall of the abutment clamping block 633 can roll against the circumferential surface of the sliding support 410. In this embodiment of the invention, the elastic damping bearing is a structure in which a spring is added between the inner ring and the outer ring of the bearing. When the inner ring and the outer ring of the bearing rotate relative to each other, they will be subjected to elastic damping. Therefore, in the initial state, the spiral sleeve 6 When the screw 610 is at the end of the left and right spiral screw, under the action of the elastic damping bearing, the clamping arm 631 is in a horizontal state and abuts against the clamping block 633 away from the winding shaft 500, which can ensure the quick loading and unloading of the winding core 400; when it is necessary to center and clamp the winding core 400, the clamping arm 631 moves to the middle position of the left and right spiral screw 610 through the connecting rotating sleeve 632 and the spiral sleeve 611, and the lower extension roller 635 rolls along the surface of the rotating part 650, and in the rotation action Under the action of the action part 650, the lower extension roller 635 is pushed by an external force, causing the clamping support arm 631 to rotate upward. The lower extension roller 635 moves to the part where the rotation action part 650 is parallel to the axis of the left and right spiral screw 610, and the abutment clamping block 633 just rotates to the position where it can be locked on the circumferential surface of the sliding support 410. As the clamping support arm 631 moves, the abutment clamping block 633 abuts against the sliding support 410 and pushes the wound core 400 to move it to the position opposite to the release wheel.

[0032] In one embodiment, such as Figures 1-4As shown, the abutting clamping block 633 is semi-circular in shape, and its inner wall has multiple equally spaced movable balls 634; the sliding support 410 includes a support sleeve 411, a connecting flange 412, and a pressure-bearing rotating ring 413. The support sleeve 411 is slidably sleeved on the rolling shaft 500. The connecting flange 412 is located at one end of the support sleeve 411 and can be fastened to the end face of the rolled core 400 by bolts. The pressure-bearing rotating ring 413 is rotatably mounted on the support sleeve 411, and a gap is left between the pressure-bearing rotating ring 413 and the rolled core 400; Embodiment of the present invention In the middle, the abutting clamping block 633 can be locked at the end of the support sleeve 411 away from the connecting flange 412. The side wall of the abutting clamping block 633 abuts against the side of the pressure bearing rotating ring 413 away from the connecting flange 412. Due to the presence of the movable ball 634 and the rotational cooperation between the pressure bearing rotating ring 413 and the support sleeve 411, the support sleeve 411 can rotate with the wound core 400 without being obstructed by the abutting clamping block 633. The gap between the pressure bearing rotating ring 413 and the wound core 400 can accommodate the end of the foil coil, preventing the end of the coil from extending too long and rubbing against the abutting clamping block 633 during rotation.

[0033] In one embodiment, such as Figures 1-4 As shown, the limiting assembly 640 includes a fixed guide post 641, a movable sleeve 642, and two limiting connecting rods 643. The fixed guide post 641 is fixed to the rolling frame 100 and positioned opposite the release wheel. The top of the fixed guide post 641 has a top plate. The movable sleeve 642 slides on the fixed guide post 641 and is connected to the top plate by an anti-slip spring 645. The two limiting connecting rods 643 are located on both sides of the two fixed guide posts 641. One end of each limiting connecting rod 643 is hinged to a limiting fixed sleeve 644, which is fixedly fitted onto a corresponding spiral sleeve 611. The other end of the limiting connecting rod 643 is connected to the outer wall of the movable sleeve 642. In the embodiment of the invention, since the movable sleeve 642 only has the degree of freedom to move vertically on the fixed guide post 641, the spiral sleeve 611 will not rotate relative to the center of the left and right spiral threaded rod 610 under the restriction of the limiting link 643 and the movable sleeve 642. The degree of freedom of the movable sleeve 642 to move vertically relative to the fixed guide post 641 will not hinder the axial movement of the spiral sleeve 611 relative to the left and right spiral threaded rod 610. Furthermore, due to the elastic force of the anti-slip spring 645, the movable sleeve 642 always has a certain tendency to move vertically. Therefore, the limiting link 643 always has a pushing or pulling force acting on the limiting fixed sleeve 644 to increase the connection between the spiral sleeve 611 and 610 and avoid slippage.

[0034] In one embodiment, such as Figure 1 , Figure 5 and Figure 6As shown, the top of the guide support frame 200 is also provided with a winding and compacting assembly 700, which includes an upper frame 710, an adjusting shaft 720, an adjusting motor 730, and a winding and rolling unit 740. The adjusting shaft 720 is rotatably mounted on the guide support frame 200, and one end of it is connected to the output end of the adjusting motor 730. One end of the upper frame 710 is connected to the upper frame 710, and the other end can extend to the upper side of the winding shaft 500. The winding and rolling unit 740 is vertically movably mounted on the upper frame 710, and the lower end of the winding and rolling unit 740 can roll against the outer surface of the wound core 400 and apply elastic pressure. In this embodiment of the invention, the foil material is... After the ends of foil sheet 310 and insulating spacer 320 are fixed to the outer surface of the rolled core 400, the adjustment motor 730 works and drives the adjustment shaft 720 to rotate. The upper frame 710 follows the adjustment shaft 720 to rotate. The end of the upper frame 710 away from the adjustment shaft 720 rotates to the upper side of the rolled core 400. At this time, the bottom of the rolling and pressing unit 740 rolls against the surface of the rolled core 400 and presses on the foil sheet 310 and insulating spacer 320. During the process of the rolled core 400 winding the foil sheet 310 and insulating spacer 320 to form a copper foil coil, the rolling and pressing unit 740 always applies pressure to the outermost copper foil coil, thereby compacting each layer of copper foil coil, reducing gaps, and avoiding the loosening of the copper foil coil.

[0035] In one embodiment, such as Figure 1 , Figure 5 and Figure 6 As shown, a blocking plate 750 is also provided on the top of the guide support frame 200. The blocking plate 750 is located on the lower side of the upper frame 710 near the adjusting shaft 720 and is fixedly connected to the top of the guide support frame 200 through a fixed side rod 760. The surface of the blocking plate 750 has a magnet. When the winding and rolling unit 740 is directly above the winding core 400, the upper frame 710 and the surface of the blocking plate 750 are in contact and the two are magnetically attracted to each other. In this embodiment of the invention, when the upper frame 710 rotates to the upper side of the winding core 400, the adjusting motor 730 stops working. The setting of the blocking plate 750 can brake the upper frame 710 to a certain extent and avoid the winding and rolling unit 740 from affecting the compaction of the copper foil coil due to external force.

[0036] In one embodiment, such as Figure 1 , Figure 5 and Figure 6As shown, the rolling and pressing unit 740 includes a rolling main frame 741 and two rolling rollers 744. At least one movable guide post 745 is provided on the upper surface of the rolling main frame 741. The movable guide post 745 slidably passes through the upper frame 710, and its top end has a movable plate 746. The movable plate 746 is connected to the upper surface of the upper frame 710 via a downward-pressing spring 747. Movable shafts 742 are provided on both sides of the rolling main frame 741. Each movable shaft 742 is connected to a movable rolling rod frame 743 via an elastic damping bearing. A freely rotatable rolling roller 744 is provided at the end of the movable rolling rod frame 743 away from the movable shaft 742. The surface of the rolling roller 744 has a rubber layer. In this embodiment, when the upper frame 710 rotates to the upper side of the rolled core 400, both rolling rollers 744 press against the outer surface of the rolled core 400. Due to the elastic force of the downward spring 747, the movable guide post 745 always tends to move downwards; therefore, when the core 400 is wound with foil sheet 310 and insulating spacer 320, the rolling roller 744 can press the foil sheet 310 and insulating spacer 320 tightly; since the movable rolling rod frame 743 and the movable shaft 742 can rotate in an elastically damped manner, the two rolling rollers 744 press on the surface of the core 400 from two positions respectively. One of them presses the foil sheet 310 and insulating spacer 320 when they just contact the surface of the core 400, and the other rolling roller 744 presses on the surface of the copper foil coil formed by subsequent winding, so that each layer of copper foil coil is wound tightly. At the same time, the vertical movement of the rolling main frame 741 and the rotation of the movable rolling rod frame 743 relative to the movable shaft 742 in an elastically damped manner can adapt to different shapes of the core 400 (circular or rectangular, etc.).

[0037] In one embodiment, such as Figure 1 , Figure 5 and Figure 6As shown, the guide support frame 200 is also provided with a tension adjustment assembly 800 located between the guide support frame 200 and the winding frame 100. The tension adjustment assembly 800 includes two tension frames 810, which are arranged opposite to each other and each is provided with a tension adjustment shaft 830. The tension adjustment shaft 830 is rotatably connected to the guide support frame 200 through an elastic damping bearing. Two tension rollers 820 are arranged between the two tension adjustment shafts 830. The ends of the tension rollers 820 are rotatably engaged with the tension frames 810. Both the sheet 310 and the insulating spacer 320 pass between the two tensioning rollers 820. A tensioning adjusting gear 840 is provided on the tensioning adjusting shaft 830. A vertically movable connecting rod 770 is also provided on the upper frame 710, and a tensioning adjusting rack 850 that meshes with the tensioning adjusting gear 840 is provided at the bottom of the connecting rod 770. An extension connecting rod 748 connected to the top of the connecting rod 770 is provided on the movable plate 746. In this embodiment of the invention, in the initial state, the elastic force of the elastic damping bearing is used to adjust the tensioning rollers 820. Roller 820 acts on foil sheet 310 and insulating spacer 320 respectively to tension them and prevent loose winding. When the end of upper frame 710 away from adjusting shaft 720 rotates to the upper side of winding core 400, tension adjusting rack 850 and tension adjusting gear 840 are engaged. If winding core 400 is not a circular structure, its protruding part will act in the opposite direction on winding rolling unit 740 after rotating to the upper side, causing it to move upward, and resulting in an increase in the pulling speed of foil sheet 310 and insulating spacer 320 connected to it. This increases the tension. The upward-moving rolling unit 740 drives the connecting rod 770 upward through the extension link 748. The meshing of the tension adjusting rack 850 and the tension adjusting gear 840 causes the tension adjusting shaft 830 to rotate. The tension frame 810 and the tension roller 820 rotate with the tension adjusting shaft 830, and the positions of the two tension rollers 820 change. This adjusts the tension of the foil sheet 310 and the insulating spacer 320, preventing the foil sheet 310 and the insulating spacer 320 from breaking due to a sudden increase in tension.

[0038] The above embodiment provides a transformer coil foil winding machine, the working principle of which is as follows:

[0039] 1. Equipment Composition and Initial State

[0040] This winding machine mainly consists of the following components:

[0041] Winding frame 100: The core frame supporting the winding mechanism.

[0042] Guide support frame 200: Provides guiding, tensioning and compaction components for foil and insulating spacers.

[0043] Foil release frame 300: Equipped with two release wheels, which respectively wind foil sheet 310 and insulating spacer 320.

[0044] The winding mechanism includes a winding shaft 500, a winding core 400, and an alignment mechanism 600, which enables precise winding of the foil.

[0045] Initial state:

[0046] The centering clamping unit 630 is horizontally placed at both ends of the winding frame 100, and the winding core 400 is not installed.

[0047] The foil sheet 310 and the insulating spacer 320 pass through the guide roller 210 and the tension adjustment assembly 800, and their ends are to be fixed.

[0048] 2. Installation and centering of rolled core

[0049] Install the rolled core 400:

[0050] The rolled core 400 (including the sliding support 410) is slid into the rolled shaft 500 from one end and pushed to the middle.

[0051] Alignment mechanism 600 starts:

[0052] The alignment motor 620 drives the left and right spiral screw 610 to rotate, and the spiral sleeve 611 moves synchronously in the opposite direction.

[0053] The centering clamping unit 630 (clamping arm 631) rotates upward under the guidance of the rotating action part 650 (pushing plate), so that the abutting clamping block 633 is rolled and engaged into the pressure-bearing rotating ring 413 of the sliding support 410 by the movable ball 634.

[0054] The two clamping units 630 move toward each other, pushing the winding core 400 to a position aligned with the release wheel, ensuring accurate winding start position.

[0055] 3. Foil winding process

[0056] Foil fixing:

[0057] The ends of the foil sheet 310 and the insulating spacer 320 are fixed to the surface of the rolled core 400.

[0058] Compactor component pressing down:

[0059] The adjustment motor 730 drives the adjustment shaft 720 to rotate, and the upper frame 710 moves the rolling and pressing unit 740 above the rolling core 400.

[0060] The rolling roller 744 presses the foil and the spacer together under the action of the spring force, and the blocking plate 750 magnetically fixes the upper frame 710.

[0061] Winding and dynamic compaction:

[0062] The winding motor 510 drives the winding shaft 500 to rotate, and the winding core 400 drives the foil sheet 310 and the insulating spacer 320 to be wound synchronously.

[0063] Double roller design:

[0064] One roller (744) compacts the initial contact point, while another compacts the wound layer, ensuring each layer is dense and gapless.

[0065] The flexible damping bearing allows the movable rolling rod 743 to rotate flexibly, accommodating rolled cores of different shapes (circular / rectangular).

[0066] Dynamic tension adjustment:

[0067] If the rolled core 400 is not circular (such as rectangular), the protruding part pushes the rolling unit 740 upward, and drives the tension adjusting gear 840 through the extension link 748 and the tension adjusting rack 850.

[0068] The tensioning frame 810 rotates to adjust the distance between the two tensioning rollers 820, thereby compensating for the tension of the foil sheet 310 and the insulating spacer 320 in real time and preventing breakage.

[0069] 4. Winding completed and core replacement

[0070] Cutting and repositioning:

[0071] The cutting device cuts the foil sheet 310 and the insulating spacer 320 to complete the coil fabrication.

[0072] The alignment motor 620 reverses, the centering clamping unit 630 retracts to both ends of the winding frame 100 and returns to its horizontal position, releasing the restriction on the sliding support 410.

[0073] Quick core replacement:

[0074] The rolled core 400 can slide out from the rotating shaft 500. After replacing the new core, the above process is repeated.

[0075] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

Claims

1. A transformer coil foil winding machine, comprising a winding frame, a guide support frame, a foil release frame, and a winding mechanism, wherein the winding frame and the guide support frame are arranged opposite to each other, the foil release frame is disposed on the guide support frame, and the foil release frame has two release wheels, the two release wheels respectively winding foil sheets and insulating spacers, characterized in that, The guide support frame is also equipped with two guide rollers that respectively guide the foil sheet and the insulating spacer; The winding mechanism is mounted on the winding frame and includes a winding shaft and an alignment structure. One end of the winding shaft is rotatably connected to the winding frame and connected to a winding motor. The winding shaft has a winding core for winding foil sheets and insulating sheets together. The winding core can slide on it, and both ends of the winding core have sliding supports. The alignment structure includes a synchronous driving unit and two centering clamping units; Two centering clamping units are arranged opposite each other and one end is connected to the synchronous drive unit. The centering clamping unit can rotate around the connection point with the synchronous drive unit. The end of the centering clamping unit away from the synchronous drive unit can be locked onto the sliding support from one side in a rolling contact manner. The synchronous drive unit is located on the winding frame and is used to drive the two centering clamping units to move synchronously in opposite directions along the axis of the winding shaft.

2. The transformer coil foil winding machine according to claim 1, characterized in that, The synchronous drive unit includes left and right rotating lead screws, an alignment motor, and a limiting assembly; The left and right spiral screws are rotatably mounted on the rolling frame and connected to the output end of the alignment motor mounted on the rolling frame. Their axes are parallel to the axis of the rolling shaft. Both ends of the left and right spiral screws are provided with spiral sleeves that are spirally engaged with them. The ends of the two centering clamping units are rotatably connected to the two spiral sleeves respectively. The limiting component is provided on the winding frame and is connected to both spiral sleeves. The limiting component can restrict the spiral sleeve from rotating relative to the center of the left and right spiral screws. The winding frame is also provided with two rotating action parts, and the end of the centering clamping unit near the spiral sleeve is also connected to the corresponding rotating action part. The rotating action part can drive the centering clamping unit in the moving state to rotate around the spiral sleeve.

3. The transformer coil foil winding machine according to claim 2, characterized in that, The rotating part is a push plate, one end of which is curved and the other end remains parallel to the axis of the left and right screw rods; The centering clamping unit includes a clamping arm and an abutting clamping block. One end of the clamping arm is provided with a connecting rotating sleeve and a lower extension roller. The connecting rotating sleeve is rotatably mounted on a corresponding spiral sleeve via an elastic damping bearing. The lower extension roller is rotatably engaged with the side of the clamping arm and abuts against the end face of the rotating part. The abutting clamping block is located at the end of the clamping arm away from the connecting rotating sleeve, and the inner wall of the abutting clamping block can roll against the circumferential surface of the sliding support.

4. The transformer coil foil winding machine according to claim 3, characterized in that, The abutting clamping block is semi-circular in shape and has multiple equally spaced movable balls on its inner wall; The sliding support includes a support sleeve, a connecting flange, and a pressure-bearing rotating ring. The support sleeve is slidably sleeved on the rolling shaft. The connecting flange is located at one end of the support sleeve and can be fastened to the end face of the rolled core with bolts. The pressure-bearing rotating ring is rotatably mounted on the support sleeve, and a gap is left between the pressure-bearing rotating ring and the rolled core.

5. The transformer coil foil winding machine according to claim 4, characterized in that, The limiting component includes a fixed guide post, a movable sleeve, and two limiting connecting rods; The fixed guide post is fixed on the rolling frame and is positioned opposite to the release wheel. The top of the fixed guide post has a top plate. The movable sleeve slides on the fixed guide post and is connected to the top plate by an anti-slip spring. Two limiting links are located on both sides of two fixed guide posts. One end of the limiting link is hinged to a limiting sleeve, which is fixedly fitted onto the corresponding spiral sleeve. The other end of the limiting link is connected to the outer wall of the movable sleeve.

6. The transformer coil foil winding machine according to claim 1, characterized in that, The top of the guide support frame is also provided with a rolling and compacting assembly, which includes an upper frame, an adjusting shaft, an adjusting motor, and a rolling and pressing unit. The adjusting shaft is rotatably mounted on the guide support frame and one end of it is connected to the output end of the adjusting motor. One end of the upper frame is connected to the upper frame body, and the other end can extend to the upper side of the rolling shaft. The rolling and pressing unit is vertically movable on the upper frame body. The lower end of the rolling and pressing unit can abut against the outer surface of the rolled core in a rolling contact manner and apply elastic pressure.

7. The transformer coil foil winding machine according to claim 6, characterized in that, The top of the guide support frame is also provided with a blocking plate. The blocking plate is located on the lower side of the upper frame near the adjusting shaft and is fixedly connected to the top of the guide support frame through a fixed side rod. The surface of the blocking plate has a magnet. When the rolling and pressing unit is directly above the rolling core, the upper frame and the surface of the blocking plate are in contact and the two are magnetically attracted to each other.

8. The transformer coil foil winding machine according to claim 7, characterized in that, The rolling unit includes a rolling frame and two rolling rollers; At least one movable guide post is provided on the upper surface of the rolling main frame. The movable guide post can slide through the upper frame and has a movable plate at the top of the movable guide post. The movable plate is connected to the upper surface of the upper frame by a downward spring. Both sides of the main rolling frame are provided with movable shafts, and each movable shaft is connected to a movable rolling rod frame through an elastic damping bearing. The end of the movable rolling rod frame away from the movable shaft is provided with a freely rotatable rolling wheel, wherein the surface of the rolling wheel has a layer of rubber.

9. The transformer coil foil winding machine according to claim 8, characterized in that, The guide support frame is also provided with a tension adjustment component located between the guide support frame and the rolling frame; The tension adjustment assembly includes two tension frames, which are arranged opposite to each other and each is equipped with a tension adjustment shaft. The tension adjustment shaft is rotatably connected to the guide support frame through an elastic damping bearing. Two tensioning rollers are arranged between the two tensioning adjustment shafts. The ends of the tensioning rollers are rotatably engaged with the tensioning frame. The foil sheet and the insulating spacer both pass through the space between the two tensioning rollers. Tensioning adjustment gears are arranged on the tensioning adjustment shafts. The upper frame is also equipped with a vertically movable connecting rod, and the bottom of the connecting rod is equipped with a tension adjusting rack that can mesh with the tension adjusting gear. The movable plate is equipped with an extension connecting rod that is connected to the top of the connecting rod.

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