An integrated forming and welding apparatus for inductance coil leads

Abstract

The application relates to the technical field of inductance manufacturing equipment, in particular to an integrated forming and welding device for inductance coil pins, which comprises a cabinet, a welding machine assembly is arranged in the cabinet, an operation platform is arranged at the top of the cabinet, a coil positioning assembly is arranged on the operation platform, symmetrically arranged mounting seats are arranged on the operation platform, coil terminal fixing assemblies are correspondingly arranged on the two mounting seats, coil terminal forming assemblies are slidably connected to the coil terminal fixing assemblies and arranged on the mounting seats, upper electrode assemblies of the welding machine assembly are fixedly arranged on the coil terminal forming assemblies, and lower electrode assemblies corresponding to the upper electrode assemblies are fixedly arranged on the coil terminal fixing assemblies; pin standby material assemblies are arranged on the two mounting seats and correspond to the coil terminal fixing assemblies. The application realizes integrated and accurate work of coil positioning, terminal forming, pin feeding and welding, is favorable for reducing process circulation time, improving single-process processing efficiency and reducing a production cycle.

Description

Technical Field

[0001] This invention relates to the field of inductor manufacturing equipment technology, and more specifically to an integrated molding and welding equipment for inductor coil leads. Background Technology

[0002] As a core passive component, the manufacturing precision and production efficiency of inductors directly affect the performance and market competitiveness of end products. The forming and soldering of coil leads are key processes in inductor manufacturing, requiring coordinated operations of terminal bending and shaping, precise lead alignment, and reliable soldering to ensure the electrical performance and structural stability of the inductor.

[0003] However, the existing inductor coil pin processing technology suffers from significant fragmentation issues. Traditional production requires multiple independent machines to complete coil positioning, terminal bending, pin feeding, and soldering operations separately. Manual transfer or complex conveyor mechanisms are needed between processes, which not only leads to long production cycles and insufficient daily capacity per workstation, but also makes it easy for coils to be damaged or mispositioned during handling. Moreover, the electrode positioning accuracy is low and the current conduction is unstable, which seriously affects the product qualification rate.

[0004] Therefore, how to achieve integrated and precise operation of coil positioning, terminal forming, pin feeding and welding, while improving production efficiency and product qualification rate, is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] In order to achieve integrated and precise operation of coil positioning, terminal forming, pin feeding and welding, and at the same time improve production efficiency and product qualification rate, this application provides an integrated forming and welding equipment for inductor coil pins.

[0006] The integrated molding and welding equipment for inductor coil leads provided in this application adopts the following technical solution:

[0007] An integrated forming and welding device for inductor coil leads includes a cabinet, an electric welding machine assembly installed inside the cabinet, an operating platform fixedly mounted on the top of the cabinet, a coil positioning assembly fixedly mounted on the operating platform, symmetrically arranged mounting seats fixedly mounted on the operating platform, and coil terminal fixing assemblies centrally symmetrically arranged around the center of the coil positioning assembly on two of the mounting seats. A coil terminal forming assembly slidably connected to the coil terminal fixing assembly is mounted on each mounting seat. An upper electrode assembly electrically connected to the electric welding machine assembly is fixedly mounted on the coil terminal forming assembly, and a lower electrode assembly corresponding to the upper electrode assembly is fixedly mounted on the coil terminal fixing assembly. Lead preparation assemblies are mounted on each of the two mounting seats corresponding to the coil terminal fixing assembly, and the lead preparation assemblies store leads for welding to the coil terminals. A control system electrically connected to the electric welding machine assembly, the coil terminal fixing assembly, and the coil terminal forming assembly is fixedly mounted on the operating platform.

[0008] Furthermore, the welding machine assembly includes a welding machine, which is fixedly installed inside the cabinet. A regulator and an output connector, which are electrically connected to the welding machine, are fixedly installed on the side wall of the cabinet. The regulator is electrically connected to the output connector, and the output connector is correspondingly electrically connected to the upper electrode assembly. Both the welding machine and the regulator are electrically connected to the control system.

[0009] Furthermore, the coil positioning assembly includes a fixed bracket, which is fixedly installed on the operating platform. A positioning pin is rotatably connected to the fixed bracket. The end of the positioning pin near the fixed bracket is rotatably connected to the fixed bracket, and the end of the positioning pin away from the fixed bracket is suspended. A rubber sleeve corresponding to the coil is fixedly fitted on the positioning pin, and the outer diameter of the rubber sleeve matches the inner diameter of the coil.

[0010] Furthermore, the coil terminal fixing assembly includes two centrally symmetrically arranged sliding plates, which are slidably connected to two mounting seats respectively. A first telescopic member is fixedly installed on the mounting seat along the length direction of the sliding plate. The telescopic end of the first telescopic member is fixedly installed on the sliding plate. An elastic pad is fixedly connected to one end of the two sliding plates that are close to each other. The first telescopic member is electrically connected to the control system.

[0011] Furthermore, the coil terminal forming assembly includes two centrally symmetrically arranged sliding blocks, which are slidably connected to the coil terminal fixing assembly. A second telescopic member is fixedly installed on the mounting base along the length direction of the coil terminal fixing assembly. The telescopic end of the second telescopic member is fixedly installed on the sliding block. The ends of the two sliding blocks that are close to each other are fixedly connected to the two terminals of the coil with mutually staggered pressing blocks. The bottom surfaces of the ends of the two pressing blocks that are close to each other are respectively chamfered on the two terminals of the coil. The second telescopic member is electrically connected to the control system.

[0012] Furthermore, the upper electrode assembly includes two sets of centrally symmetrically arranged welding machine connectors, a first welding electrode, and a first electrode connecting block. Welding electrode terminals are fixedly installed on the welding machine connectors, and these terminals are electrically connected to the welding machine assembly via wires. The two sliding blocks and the extrusion block in the coil terminal forming assembly each have corresponding welding machine connector mounting holes, first electrode mounting holes, and first electrode connecting block mounting holes on each set of welding machine connectors, the first welding electrode, and the first electrode connecting block. The welding machine connector mounting hole is located at the center of the top surface of the sliding block; the first electrode mounting hole is located at the front of the top surface of the extrusion block and penetrates the extrusion block; and the first electrode connecting block mounting hole is located on the bottom surface of the sliding block near the outer edge and corresponding to the lower electrode assembly. The welding machine connector, the first welding electrode, and the first electrode connecting block are all correspondingly embedded in the welding machine connector mounting holes, the first electrode mounting holes, and the first electrode connecting block mounting holes.

[0013] Furthermore, the lower electrode assembly includes two sets of second welding electrodes and second electrode connecting blocks arranged symmetrically in a central configuration. The second welding electrodes and the second electrode connecting blocks are integrally formed from copper material by casting. The sliding plate in the coil terminal fixing assembly has second welding electrode mounting holes and second electrode connecting block mounting holes corresponding to each set of second welding electrodes and second electrode connecting blocks. The second welding electrodes and the second electrode connecting blocks are respectively embedded in the second welding electrode mounting holes and the second electrode connecting block mounting holes.

[0014] Furthermore, the pin preparation assembly includes a pin storage box, which stores a plurality of vertically stacked pins. The pin storage box is fixedly mounted on the mounting base. The bottom of the pin storage box is slidably connected to the top surface of the sliding plate in the coil terminal fixing assembly. The top surface of the sliding plate in the coil terminal fixing assembly is provided with a feeding groove corresponding to the bottom of the pin storage box. A check mechanism is installed on the mounting base corresponding to the feeding groove.

[0015] Furthermore, the check mechanism includes a rotating shaft, which is rotatably connected to the mounting base at a position corresponding to the upper part of the feed trough. A check plate is fixedly connected to the rotating shaft, and the check plate swings toward the pin storage box. The bottom surface of the check plate away from the rotating shaft is provided with a buckle at the end corresponding to the pin, and the end of the feed trough is provided with an oblique opening corresponding to the buckle.

[0016] Furthermore, the control system includes a PLC controller, which is electrically connected to the welding machine assembly, the coil terminal fixing assembly, and the coil terminal forming assembly. The PLC controller is also electrically connected to a display, control buttons, and a control pedal.

[0017] Beneficial effects achieved:

[0018] This application achieves the integrated and synchronous completion of coil positioning, terminal fixing, bending and forming, lead preparation and welding operations by setting up an integrated layout of coil positioning component, coil terminal fixing component, coil terminal forming component, upper electrode assembly, lower electrode assembly and lead preparation component on the operating platform, and coordinating with control system linkage welding machine component, first telescopic component, second telescopic component and check mechanism. This is beneficial to reduce process flow time, improve single process processing efficiency and shorten production cycle.

[0019] This application achieves the effect of consistent coil terminal fixing position, bending size and welding point height by centrally symmetrically arranging the coil terminal fixing component, coil terminal forming component, upper electrode assembly and lower electrode assembly with the coil positioning component as the center, and by precisely matching the positioning pin and rubber sleeve, guiding the forming of the extrusion block chamfer and embedding the electrode assembly. This helps to reduce product size error and improve the consistency and pass rate of mass production.

[0020] This application achieves convenient equipment operation, precise control of process parameters, and adaptability to the processing of coils of different specifications by using the PLC controller of the control system to link the display, control buttons, and control pedals. Combined with the programmable adjustment of the first and second telescopic components and the modular installation structure of each component, it helps to reduce the intensity of manual operation, reduce human intervention errors, improve production flexibility, and broaden the applicability of the equipment. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of one embodiment of this application.

[0022] Figure 2 This is a structural exploded view of one embodiment of this application.

[0023] Figure 3This is a schematic diagram of the internal structure of one embodiment of this application.

[0024] Figure 4 This is an exploded view of the installation structure of the welding machine assembly in one embodiment of this application.

[0025] Figure 5 This is an exploded view of the installation structure of the coil positioning assembly in one embodiment of this application.

[0026] Figure 6 This is an exploded view of the installation structure of the coil terminal fixing assembly in one embodiment of this application.

[0027] Figure 7 This is an exploded view of the installation structure of the coil terminal forming assembly in one embodiment of this application.

[0028] Figure 8 This is an exploded view of the mounting structure of the upper electrode assembly in one embodiment of this application.

[0029] Figure 9 This is an exploded view of the mounting structure of the lower electrode assembly in one embodiment of this application.

[0030] Figure 10 This is an exploded view of the mounting structure of the pin preparation assembly in one embodiment of this application.

[0031] Figure 11 yes Figure 3 Enlarged schematic diagram of Part I of the structure.

[0032] Explanation of reference numerals in the attached drawings: 100, cabinet; 101, operating platform; 102, mounting base; 200, welding machine assembly; 201, welding machine; 202, regulator; 203, output connector; 300, coil positioning assembly; 301, fixed bracket; 302, positioning pin; 303, rubber sleeve; 400, coil terminal fixing assembly; 401, sliding plate; 402, first telescopic component; 403, elastic pad; 500, coil terminal forming assembly; 501, sliding block; 502, second telescopic component; 503, extrusion block; 504, chamfer; 600, upper electrode assembly; 601, welding machine connection base; 602, first welding electrode; 603. First electrode connecting block; 604. Welding electrode terminal; 605. Welding machine connecting seat mounting hole; 606. First electrode mounting hole; 607. First electrode connecting block mounting hole; 700. Lower electrode assembly; 701. Second welding electrode; 702. Second electrode connecting block; 703. Second welding electrode mounting hole; 704. Second electrode connecting block mounting hole; 800. Pin preparation assembly; 801. Pin storage box; 802. Feed chute; 803. Rotating shaft; 804. Check plate; 805. Inverted thread; 806. Angled opening; 900. Control system; 901. Display; 902. Control button; 903. Control pedal. Detailed Implementation

[0033] The following combination Figure 1 — Figure 11 This application will be described in further detail.

[0034] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the present invention and 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, and therefore should not be construed as a limitation of the present 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.

[0035] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0036] This application discloses an integrated molding and welding device for inductor coil pins.

[0037] Please refer to the above as well. Figures 1 to 11 In one embodiment of this application, an integrated forming and welding device for inductor coil pins includes a cabinet 100. A welding machine assembly 200 is installed inside the cabinet 100. An operating platform 101 is fixedly installed on the top of the cabinet 100. A coil positioning assembly 300 is fixedly installed on the operating platform 101. Symmetrically arranged mounting seats 102 are fixedly installed on the operating platform 101. Coil terminal fixing assemblies 400, centrally symmetrically arranged around the center of the coil positioning assembly 300, are correspondingly installed on the two mounting seats 102. The coil terminal fixing assemblies 400 are used to fix the coil terminals. A coil terminal forming assembly 500, slidably connected to the coil terminal fixing assembly 400, is installed on the mounting seats 102. The coil terminal forming assembly 500 is used to bend and form the coil terminals. A welding machine assembly is fixedly installed on the coil terminal forming assembly 500. The upper electrode assembly 600 is electrically connected to the coil terminal fixing assembly 400, and the lower electrode assembly 700 corresponding to the upper electrode assembly 600 is fixedly installed on the coil terminal fixing assembly 400. While the coil terminal forming assembly 500 bends and forms the coil terminal, the upper electrode assembly 600 and the lower electrode assembly 700 will form an electrical connection. Both mounting bases 102 are equipped with lead preparation assemblies 800 corresponding to the coil terminal fixing assembly 400. The lead preparation assemblies 800 store leads for welding to the coil terminal. While the driving sliding plate 401 clamps the coil terminal, the coil terminal fixing assembly 400 simultaneously transports the leads in the lead preparation assemblies 800 to the welding position. The operating platform 101 is fixedly installed with a control system 900 that is electrically connected to the welding machine assembly 200, the coil terminal fixing assembly 400, and the coil terminal forming assembly 500.

[0038] During operation, the operator first places the inductor coil onto the coil positioning assembly 300 on the operating platform 101, achieving precise positioning of the coil. Subsequently, the coil terminal fixing assembly 400 is activated to clamp and fix the coil terminals, providing a stable foundation for subsequent processing.

[0039] The control system 900 synchronously sends working signals to the welding machine assembly 200, the coil terminal forming assembly 500, and the lead preparation assembly 800. The coil terminal forming assembly 500 slides along the mounting base 102 to bend and form the coil terminal; at the same time, the lead preparation assembly 800 outputs the stored leads to the coil terminal fixing assembly 400, so that the leads are precisely fitted to the bent and formed coil terminal.

[0040] During the bending process of the coil terminal forming assembly 500, the upper electrode assembly 600 fixed at its top forms an electrical connection with the lower electrode assembly 700 on the coil terminal fixing assembly 400. The welding machine assembly 200 outputs welding current through this electrical connection to complete the integrated welding of the pins and the coil terminals. After welding is completed, each assembly is reset under the control of the control system 900, and the operator can then remove the processed inductor coil.

[0041] Please refer to the above as well. Figures 1 to 11 In one specific embodiment of this application, the welding machine assembly 200 includes a welding machine 201, which is fixedly installed inside a cabinet 100. A regulator 202 and an output connector 203, which are electrically connected to the welding machine 201, are fixedly installed on the side wall of the cabinet 100. The regulator 202 and the output connector 203 are electrically connected, and the output connector 203 is correspondingly electrically connected to the upper electrode assembly 600. Both the welding machine 201 and the regulator 202 are electrically connected to the control system 900.

[0042] In the overall workflow of the equipment, the control system 900 first sends a synchronous working command to the welding machine assembly 200. Upon receiving the command, the welding machine 201 starts, and simultaneously, the control system 900 transmits preset welding parameter signals to the regulator 202. The regulator 202 adjusts key parameters such as welding current and voltage according to the signal, and the adjusted parameter signals are synchronously fed back to the welding machine 201 to ensure that the welding machine 201 outputs welding energy that meets the processing requirements. The welding current generated by the welding machine 201 is transmitted to the output connector 203 through an electrical connection, and the output connector 203 stably conducts the current to the corresponding upper electrode assembly 600. When the coil terminal forming assembly 500 drives the upper electrode assembly 600 to contact and form an electrical connection with the lower electrode assembly 700, the welding current forms a closed loop through the upper electrode assembly 600 and the lower electrode assembly 700, completing the welding operation between the pin and the coil terminal.

[0043] Please refer to the above as well. Figures 1 to 11 In one specific embodiment of this application, the welding machine 201 is a modified industrial frequency AC welding machine, such as the BX1-315 welding machine. This welding machine not only has a simple structure, low failure rate, and low maintenance cost, making it suitable for large-scale continuous production scenarios, but it can also provide sufficient welding energy for coil terminal welding in a long-term stable manner. Moreover, it has strong overload capacity and can meet the welding requirements of pins of different thicknesses. With the regulator 202, the current can be flexibly adjusted, making it widely adaptable.

[0044] It is understood that in other embodiments of this application, the welding machine 201 can also be modified from a welding machine such as an inverter DC welding machine, for example, the ZX7-250 inverter DC welding machine. This welding machine not only has stable current output and concentrated welding arc, but also can accurately control welding heat, avoiding burn-out and cold solder joints when welding coil terminals and pins, thus meeting the needs of precision welding. Moreover, it has significant energy-saving effect, saving 30%-50% of electricity compared to traditional models, and is small in size and light in weight, making it easy to install inside the cabinet 100 without taking up too much space.

[0045] Please refer to the above as well. Figures 1 to 11 In one specific embodiment of this application, the coil positioning assembly 300 includes a fixed bracket 301, which is L-shaped and fixedly mounted on the operating platform 101. A positioning pin 302 is rotatably connected to the fixed bracket 301. One end of the positioning pin 302 near the fixed bracket 301 is rotatably connected to the fixed bracket 301, and the other end of the positioning pin 302 away from the fixed bracket 301 is suspended. A rubber sleeve 303 corresponding to the coil is fixedly fitted on the positioning pin 302, and the outer diameter of the rubber sleeve 303 matches the inner diameter of the coil.

[0046] Before starting the equipment, the operator aligns the inductor coil to be processed with the suspended end of the positioning pin 302. Since the outer diameter of the rubber sleeve 303 matches the inner diameter of the coil, the coil can be directly fitted onto the outside of the rubber sleeve 303 on the positioning pin 302, achieving initial coil positioning. The fixed bracket 301 is L-shaped and fixedly mounted on the operating platform 101, providing stable support for the positioning pin 302. The positioning pin 302 is rotatably connected to the fixed bracket 301. When fitting the coil, the positioning pin 302 can be slightly rotated according to the operating angle, improving the ease of coil installation. After the coil is fitted, the rubber sleeve 303 tightly fits against the inner wall of the coil, limiting the radial displacement of the coil during processing; the cooperation between the fixed bracket 301 and the positioning pin 302 limits the axial wobbling of the coil, ultimately achieving precise positioning of the coil in the welding and forming processes. Once the entire processing is complete, the operator can simply reverse the direction and remove the coil.

[0047] Please refer to the above as well. Figures 1 to 11 In one specific embodiment of this application, the coil terminal fixing assembly 400 includes two centrally symmetrically arranged sliding plates 401. The two sliding plates 401 are slidably connected to two mounting seats 102 respectively. A first telescopic member 402 is fixedly installed on the mounting seat 102 along the length direction of the sliding plate 401. The telescopic end of the first telescopic member 402 is fixedly installed on the sliding plate 401. An elastic pad 403 is fixedly connected to one end of the two sliding plates 401 that is close to each other. The first telescopic member 402 is electrically connected to the control system 900.

[0048] During operation, after the coil is positioned by the coil positioning assembly 300, the control system 900 sends a drive command to the first telescopic member 402. The first telescopic member 402 is fixedly mounted on the mounting base 102, and its telescopic end is connected to the sliding plate 401. Upon receiving the command, it extends along the length of the sliding plate 401, pushing the two sliding plates 401 to slide towards each other along the mounting base 102. When the two sliding plates 401 approach each other to a preset position, the elastic pads 403 at their ends contact the two terminals of the coil respectively. The pushing force of the first telescopic member 402 forms a clamping force, firmly fixing the coil terminals in the preset position, providing stable support for subsequent bending and welding. After the coil terminal forming and lead welding processes are completed, the control system 900 sends a reset command to the first telescopic member 402. The first telescopic member 402 retracts, causing the two sliding plates 401 to slide in opposite directions and move away from each other along the mounting base 102. The elastic pads 403 disengage from the coil terminals, releasing the fixed state, making it convenient for the operator to remove the processed coil.

[0049] Please refer to the above as well. Figures 1 to 11 In one specific embodiment of this application, the coil terminal forming assembly 500 includes two centrally symmetrically arranged sliding blocks 501. The two sliding blocks 501 are slidably connected to the coil terminal fixing assembly 400. A second telescopic member 502 is fixedly installed on the mounting base 102 along the length direction of the coil terminal fixing assembly 400. The telescopic end of the second telescopic member 502 is fixedly installed on the sliding blocks 501. The two ends of the two sliding blocks 501 that are close to each other are fixedly connected to the two terminals of the coil with mutually offset pressing blocks 503. The bottom surfaces of the two ends of the two pressing blocks 503 that are close to each other are respectively provided with chamfers 504 on the two terminals of the coil. The second telescopic member 502 is electrically connected to the control system 900.

[0050] During operation, after the coil terminals are clamped and fixed by the coil terminal fixing assembly 400, the control system 900 sends a drive signal to the second telescopic member 502. Upon receiving the signal, the telescopic end of the second telescopic member 502 extends, pushing the sliding block 501 to slide towards each other along the coil terminal fixing assembly 400. As the sliding block 501 approaches, the pressing blocks 503, whose ends are staggered, gradually approach the two terminals of the coil. The chamfer 504 at the bottom of the pressing block 503 first contacts the terminal, guiding the terminal to deform along the direction of the chamfer 504. When sliding to the preset position, the pressing block 503 applies stable pressure to the terminal, completing the bending and forming at the preset angle. After forming, a welding command is sent through the control system 900. After welding is completed, a reset command is sent through the control system 900 to control the second telescopic member 502 to retract, causing the sliding block 501 and the pressing block 503 to slide and reset in opposite directions, waiting for the next working cycle.

[0051] Please refer to the above as well. Figures 1 to 11In one specific embodiment of this application, both the first telescopic member 402 and the second telescopic member 502 are configured as electric telescopic rods, such as the FY011 type programmable electric telescopic rod. This electric telescopic rod not only supports direct programming control by a PLC controller, but also allows for the preset of multiple sets of telescopic stroke parameters through the control system 900. This eliminates the need for manual adjustment, enabling adaptation to different coil terminal fixing and forming requirements, and making production specification switching more efficient. Furthermore, it has a built-in limit sensor that can automatically identify the telescopic limit position, preventing excessive telescopic damage to the sliding plate 401, sliding block 501, or coil, thereby extending equipment lifespan and reducing maintenance costs.

[0052] It is understood that in other embodiments of this application, the first telescopic member 402 and the second telescopic member 502 may also be configured as a cylinder, a hydraulic telescopic member, or other drive mechanism capable of reciprocating movement.

[0053] Please refer to the above as well. Figures 1 to 11 In one specific embodiment of this application, the upper electrode assembly 600 includes two sets of centrally symmetrically arranged welding machine connectors 601, a first welding electrode 602, and a first electrode connecting block 603. The welding machine connectors 601, the first welding electrode 602, and the first electrode connecting block 603 are integrally formed from copper material by casting. A welding electrode terminal 604 is fixedly installed on the welding machine connector 601, and the welding electrode terminal 604 is electrically connected to the output connector 203 in the welding machine assembly 200 through a wire. The two sliding blocks 501 and the pressing block 503 in the coil terminal forming assembly 500 correspond to each set of welding machine connectors 601, the first welding electrode 602, and the first electrode connecting block 603. Each of the 03 components has a corresponding welding machine connector mounting hole 605, a first electrode mounting hole 606, and a first electrode connecting block mounting hole 607. The welding machine connector mounting hole 605 is located in the center of the top surface of the sliding block 501. The first electrode mounting hole 606 is located in the front of the top surface of the extrusion block 503 and penetrates through the extrusion block 503. The first electrode connecting block mounting hole 607 is located on the bottom surface of the sliding block 501 near the outer side and corresponds to the lower electrode assembly 700. The welding machine connector 601, the first welding electrode 602, and the first electrode connecting block 603 are all correspondingly embedded in the welding machine connector mounting hole 605, the first electrode mounting hole 606, and the first electrode connecting block mounting hole 607.

[0054] During operation, after the welding machine assembly 200 is started, the welding current is transmitted through the output connector 203 to the welding electrode terminal 604 via wires. The welding machine connector 601, the first welding electrode 602, and the first electrode connecting block 603 are integrally cast from copper, exhibiting excellent conductivity. After the current enters from the welding electrode terminal 604, it is quickly conducted through the welding machine connector 601 to the first welding electrode 602 and the first electrode connecting block 603, achieving uniform current distribution.

[0055] When the control system 900 drives the second telescopic component 502 to push the sliding block 501 to slide, the upper electrode assembly 600, which is embedded in the sliding block 501 and the extrusion block 503 corresponding to the welding machine connection seat mounting hole 605, the first electrode mounting hole 606, and the first electrode connecting block mounting hole 607, moves synchronously with the sliding block 501. As the extrusion block 503 bends and shapes the coil terminals, the first electrode connecting block 603 moves closer to the lower electrode assembly 700 with the sliding block 501, and finally contacts the lower electrode assembly 700 to form a closed circuit. At this time, the two sets of symmetrically arranged first welding electrodes 602 and the lower electrode assembly 700 will be aligned with the contact points of the two terminals and two pins of the coil, and precise welding will be completed through the conducted welding current. After welding is completed, the sliding block 501 resets, the first electrode connecting block 603 separates from the lower electrode assembly 700, the current transmission is interrupted, and the upper electrode assembly 600 returns to its initial position to wait for the next operation.

[0056] Please refer to the above as well. Figures 1 to 11 In one specific embodiment of this application, the lower electrode assembly 700 includes two sets of second welding electrodes 701 and second electrode connecting blocks 702 arranged centrally symmetrically. The second welding electrodes 701 and second electrode connecting blocks 702 are integrally formed from copper material by casting. The sliding plate 401 in the coil terminal fixing assembly 400 has a second welding electrode mounting hole 703 and a second electrode connecting block mounting hole 704 corresponding to each set of second welding electrodes 701 and second electrode connecting blocks 702. The second welding electrodes 701 and second electrode connecting blocks 702 are respectively embedded in the second welding electrode mounting holes 703 and second electrode connecting block mounting holes 704.

[0057] During operation, the second welding electrode 701 and the second electrode connecting block 702 are respectively embedded in the sliding plate 401 through the second welding electrode mounting hole 703 and the second electrode connecting block mounting hole 704. They are initially positioned with the coil terminal fixing assembly 400, and the two sets of components are centrally symmetrically arranged, precisely corresponding to the position of the upper electrode assembly 600.

[0058] When the coil terminal forming assembly 500 moves the upper electrode assembly 600 along with the sliding block 501, the first electrode connecting block 603 of the upper electrode assembly 600 gradually approaches the second electrode connecting block 702 until the two are aligned and connected, forming a complete welding current loop. The welding current is conducted through the first electrode connecting block 603 to the second electrode connecting block 702, and then through the integrally formed second welding electrode 701 to the contact point between the coil terminal and the pin, cooperating with the first welding electrode 602 to achieve precise welding. After welding is completed, the coil terminal forming assembly 500 resets, the first electrode connecting block 603 separates from the second electrode connecting block 702, the welding current loop is broken, and the lower electrode assembly 700 remains in the initial position, waiting for the next working cycle.

[0059] Please refer to the above as well. Figures 1 to 11 In one specific embodiment of this application, the sliding plate 401, the sliding block 501, and the extrusion block 503 are all made of insulating materials with good structural strength, such as glass fiber reinforced nylon such as PA66+30%GF. This material not only has excellent insulation properties, effectively blocking the conduction of welding current and preventing current from being conducted through the sliding plate 401 and the sliding block 501 to the mounting base 102 or the control system 900, thus ensuring the safety of the equipment circuit, but also has a tensile strength of up to 150MPa, sufficient structural rigidity, and can withstand the driving force of the first telescopic member 402 and the second telescopic member 502, as well as the impact force when the extrusion block 503 bends the terminal, and is not easily deformed during long-term use; at the same time, it has good wear resistance, which helps to reduce sliding friction loss with the mounting base 102 and the sliding plate 401.

[0060] Please refer to the above as well. Figures 1 to 11 In one specific embodiment of this application, the pin preparation assembly 800 includes a pin storage box 801, which stores a plurality of vertically stacked pins. The pin storage box 801 is fixedly mounted on the mounting base 102. The bottom of the pin storage box 801 is slidably connected to the top surface of the sliding plate 401 in the coil terminal fixing assembly 400. The top surface of the sliding plate 401 in the coil terminal fixing assembly 400 is provided with a feeding groove 802 corresponding to the bottom of the pin storage box 801. A check mechanism is installed on the mounting base 102 corresponding to the feeding groove 802 to prevent the pins from retracting.

[0061] During operation, the pin storage box 801 is fixedly mounted on the mounting base 102, and several pins are vertically stacked inside, with its bottom slidably connected to the top surface of the sliding plate 401.

[0062] When the control system 900 drives the first telescopic component 402 to push the sliding plate 401 to slide towards each other, the feeding groove 802 on the top surface of the sliding plate 401 moves with the sliding plate 401 and gradually aligns with the bottom outlet of the pin storage box 801. The pins in the pin storage box 801 fall into the feeding groove 802 under the action of gravity. As the sliding plate 401 continues to slide to the fixed position of the coil terminal, the pins in the feeding groove 802 are accurately delivered to the preset welding position next to the coil terminal, completing the material preparation and preparing for the subsequent welding process.

[0063] Please refer to the above as well. Figures 1 to 11 In one specific embodiment of this application, the check mechanism includes a rotating shaft 803, which is rotatably connected to the mounting base 102 at a position above the feed trough 802. A check plate 804 is fixedly connected to the rotating shaft 803. The check plate 804 swings toward the pin storage box 801. The bottom surface of the check plate 804 away from the rotating shaft 803 is provided with a buckle 805 at the end corresponding to the pin. The end of the feed trough 802 is provided with a slanted opening 806 corresponding to the buckle 805.

[0064] During operation, when the sliding plate 401 slides away from the coil under the drive of the first telescopic member 402, the feed trough 802 moves synchronously with the sliding plate 401, gradually aligning with the bottom outlet of the pin storage box 801, and the pins fall from the pin storage box 801 into the feed trough 802. When the sliding plate 401 slides closer to the coil under the drive of the first telescopic member 402, the feed trough 802 moves synchronously with the sliding plate 401, gradually separating from the bottom outlet of the pin storage box 801, and driving the pins to move synchronously closer to the coil; the check plate 804 will always maintain a downward swinging trend under the action of gravity. When the sliding plate 401 slides away from the coil again under the drive of the first telescopic member 402, the buckle 805 will tightly hook the end of the pin through the inclined opening 806, thereby preventing the pin from retracting, so as to ensure that the next pin can reliably enter the feed trough 802. In this way, multiple pins inside the feed trough 802 will abut against each other, stably and reliably conveying the first pin to the welding position.

[0065] Please refer to the above as well. Figures 1 to 11In one specific embodiment of this application, the control system 900 includes a PLC controller, which is electrically connected to the welding machine assembly 200, the coil terminal fixing assembly 400, and the coil terminal forming assembly 500. The PLC controller is electrically connected to a display 901, control buttons 902, and a control pedal 903. The display 901 and control buttons 902 are fixedly mounted on the operating platform 101, and the control pedal 903 is placed on the ground. The control buttons 902 are used to control the first telescopic member 402 in the coil terminal fixing assembly 400 and the second telescopic member 502 in the coil terminal forming assembly 500. The control pedal 903 is used to control the welding machine 201 in the welding machine assembly 200.

[0066] During operation, after the equipment starts, the PLC controller first completes initialization, and the display 901 lights up simultaneously, showing the initial status parameters of the welding machine assembly 200, coil terminal fixing assembly 400, and coil terminal forming assembly 500. After the operator positions the coil using the coil positioning assembly 300, they press the control button 902 on the operating platform 101. The control signal is transmitted to the PLC controller, which then sends a drive command to the first telescopic component 402, causing the coil terminal fixing assembly 400 to clamp and fix the coil terminal. According to the processing requirements, relevant parameters are preset using the control button 902. After receiving the command, the PLC controller sends a signal to the second telescopic component 502, driving the coil terminal forming assembly 500 to bend and form the terminal, while simultaneously linking the lead feeding assembly 800 to feed the lead. When the terminal is formed in place and the lead is attached, the operator steps on the control pedal 903 on the ground. After receiving the signal, the PLC controller starts the welding machine 201 in the welding machine assembly 200, transmitting welding current to the upper electrode assembly 600 through the output connector 203 to complete the welding operation. After processing is completed, the PLC controller issues a reset command, all components return to their initial positions, and the display 901 updates to show the processing completion status, waiting for the next operation command.

[0067] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An integrated molding and welding device for inductor coil leads, characterized in that: The system includes a cabinet, inside which a welding machine assembly is installed. An operating platform is fixedly mounted on the top of the cabinet, and a coil positioning assembly is fixedly mounted on the operating platform. Symmetrically arranged mounting seats are fixedly mounted on the operating platform, and coil terminal fixing assemblies are centrally symmetrically arranged around the center of the coil positioning assembly on two of the mounting seats. A coil terminal forming assembly, slidably connected to the coil terminal fixing assembly, is mounted on each mounting seat. An upper electrode assembly, electrically connected to the welding machine assembly, is fixedly mounted on the coil terminal forming assembly, and a lower electrode assembly, corresponding to the upper electrode assembly, is fixedly mounted on the coil terminal fixing assembly. Each of the two mounting seats has a lead preparation assembly corresponding to the coil terminal fixing assembly, storing leads for welding the coil terminals. A control system, electrically connected to the welding machine assembly, the coil terminal fixing assembly, and the coil terminal forming assembly, is fixedly mounted on the operating platform. The coil positioning assembly includes a fixing bracket, and the coil terminal fixing assembly includes two sliding plates arranged symmetrically in a central manner, with the two sliding plates slidably connected to the two mounting bases respectively. The coil terminal forming assembly includes two sliding blocks arranged in a centrally symmetrical manner. The two sliding blocks are slidably connected to two sliding plates in the coil terminal fixing assembly. The ends of the two sliding blocks that are close to each other are fixedly connected to two terminals of the coil with mutually offset pressing blocks. The upper electrode assembly includes two sets of centrally symmetrically arranged welding machine connectors, a first welding electrode, and a first electrode connecting block. The two sliding blocks and the extrusion block in the coil terminal forming assembly each have corresponding welding machine connector mounting holes, first electrode mounting holes, and first electrode connecting block mounting holes on each set of welding machine connectors, first welding electrodes, and first electrode connecting blocks. The welding machine connectors, first welding electrodes, and first electrode connecting blocks are all correspondingly embedded in the welding machine connector mounting holes, first electrode mounting holes, and first electrode connecting block mounting holes. The lower electrode assembly includes two sets of second welding electrodes and second electrode connecting blocks arranged centrally symmetrically. The sliding plate in the coil terminal fixing assembly has second welding electrode mounting holes and second electrode connecting block mounting holes corresponding to each set of second welding electrodes and second electrode connecting blocks. The second welding electrodes and second electrode connecting blocks are respectively embedded in the second welding electrode mounting holes and second electrode connecting block mounting holes. The pin preparation assembly includes a pin storage box, and the top surface of the sliding plate in the coil terminal fixing assembly is provided with a feeding groove corresponding to the bottom of the pin storage box.

2. The integrated molding and welding equipment for inductor coil leads according to claim 1, characterized in that: The welding machine assembly includes a welding machine, which is fixedly installed inside the cabinet. A regulator and an output connector, which are electrically connected to the welding machine, are fixedly installed on the side wall of the cabinet. The regulator is electrically connected to the output connector, and the output connector is correspondingly electrically connected to the upper electrode assembly. Both the welding machine and the regulator are electrically connected to the control system.

3. The integrated molding and welding equipment for inductor coil leads according to claim 1, characterized in that: The fixed bracket is fixedly installed on the operating platform. A positioning pin is rotatably connected to the fixed bracket. The end of the positioning pin near the fixed bracket is rotatably connected to the fixed bracket, and the end of the positioning pin away from the fixed bracket is suspended. A rubber sleeve corresponding to the coil is fixedly fitted on the positioning pin. The outer diameter of the rubber sleeve matches the inner diameter of the coil.

4. The integrated molding and welding equipment for inductor coil leads according to claim 1, characterized in that: A first telescopic member is fixedly installed on the mounting base along the length of the sliding plate. The telescopic end of the first telescopic member is fixedly installed on the sliding plate, and an elastic pad is fixedly connected to one end of the two sliding plates that are close to each other. The first telescopic member is electrically connected to the control system.

5. The integrated molding and welding equipment for inductor coil leads according to claim 1, characterized in that: A second telescopic member is fixedly installed on the mounting base along the length direction of the coil terminal fixing assembly. The telescopic end of the second telescopic member is fixedly installed on the sliding block. The bottom surfaces of the two pressing blocks that are close to each other are respectively chamfered on the two terminals of the coil. The second telescopic member is electrically connected to the control system.

6. The integrated molding and welding equipment for inductor coil leads according to claim 1, characterized in that: A welding electrode terminal is fixedly installed on the welding machine connector, and the welding electrode terminal is electrically connected to the welding machine assembly through a wire; the welding machine connector mounting hole is opened at the center of the top surface of the sliding block, the first electrode mounting hole is opened at the front of the top surface of the extrusion block and penetrates the extrusion block, and the first electrode connecting block mounting hole is opened at the bottom surface of the sliding block near the outer side and corresponding to the lower electrode assembly.

7. The integrated molding and welding equipment for inductor coil leads according to claim 1, characterized in that: The second welding electrode and the second electrode connecting block are integrally formed from copper material by casting.

8. The integrated molding and welding equipment for inductor coil leads according to claim 1, characterized in that: The pin storage box stores several vertically stacked pins. The pin storage box is fixedly mounted on the mounting base. The bottom of the pin storage box is slidably connected to the top surface of the sliding plate in the coil terminal fixing assembly. A check mechanism is installed on the mounting base corresponding to the feed chute.

9. The integrated molding and welding equipment for inductor coil leads according to claim 8, characterized in that: The check mechanism includes a rotating shaft, which is rotatably connected to the mounting base at a position above the feed trough. A check plate is fixedly connected to the rotating shaft. The check plate swings toward the pin storage box. The bottom surface of the check plate away from the rotating shaft is provided with a buckle at the end corresponding to the pin. The end of the feed trough is provided with an angled opening corresponding to the buckle.

10. The integrated molding and welding equipment for inductor coil leads according to claim 1, characterized in that: The control system includes a PLC controller, which is electrically connected to the welding machine assembly, the coil terminal fixing assembly, and the coil terminal forming assembly. The PLC controller is also electrically connected to a display, control buttons, and a control pedal.

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