Magnetorheological coil machining device and machining method for shock absorber

Abstract

The invention relates to a magnetorheological coil machining device and method for a shock absorber, and belongs to the technical field of coil machining. The magnetorheological coil machining device comprises a rack used for supporting, and an iron core clamping mechanism arranged on the rack and used for clamping a coil iron core; the joint pressure injection mechanism is arranged on the rack and is used for injecting a joint into the coil iron core; the wire harness stripping mechanism is arranged on the rack and is used for stripping an insulating layer of the wire harness; the coil winding mechanism is arranged on the rack and is used for winding a coil; the welding mechanism is arranged on the rack and used for welding the wire harness outgoing line; the glue filling mechanism is arranged on the rack and used for filling glue into the coil; and the control mechanism is arranged on the rack and electrically connected with the iron core clamping mechanism, the joint pressure injection mechanism, the wire harness peeling mechanism, the coil winding mechanism, the welding mechanism and the glue filling mechanism. According to the device, a plurality of working procedures are integrated on one rack, so that the transfer time of workpieces among different working procedures is shortened, and the machining efficiency is remarkably improved.

Description

Technical Field

[0001] This application belongs to the field of coil processing technology, specifically relating to a magnetorheological coil processing device and processing method for vibration dampers. Background Technology

[0002] In the traditional manufacturing process of magnetorheological coils for vibration dampers, manual or semi-automated operations are typically employed. Specific steps include manually clamping the coil core, crimping connectors, stripping the insulation layer of the wire harness, winding the coil, soldering the wire harness leads, and applying adhesive. These traditional methods have many drawbacks, such as cumbersome operation, low efficiency, high labor costs, and inconsistent product quality. Furthermore, manual operation is prone to human error, affecting the consistency and reliability of the coil, making it difficult to meet the high precision and efficiency requirements of modern industry.

[0003] For example, Chinese patent CN118658725A discloses a coil winding module and device. This technology winds the coil separately from the beginning and end of the wire to control the length of the wire end and the number of turns of the coil. However, due to the structural characteristics of magnetorheological coils, the coil needs to be processed into two sets of coils with opposite winding directions. Therefore, this technology cannot meet the processing requirements of magnetorheological coils, and there is an urgent need to design a dedicated magnetorheological coil processing device. Summary of the Invention

[0004] To solve the above problems, the technical solution adopted in this application is: In a first aspect, this application provides a processing apparatus for magnetorheological coils for vibration dampers, comprising: The frame is used for support. The iron core clamping mechanism is mounted on the frame and is used to clamp the coil iron core; The connector injection mechanism, mounted on the frame, is used to inject the connector into the coil core. The wire harness stripping mechanism, mounted on the frame, is used to strip the insulation layer of the wire harness; A coil winding mechanism, mounted on a frame, is used for winding coils; The welding mechanism, mounted on the frame, is used for welding wire harness leads; The glue-filling mechanism, mounted on the frame, is used to fill the coil with glue. The control mechanism is mounted on the frame and is electrically connected to the core clamping mechanism, connector injection mechanism, wire harness stripping mechanism, coil winding mechanism, welding mechanism, and glue dispensing mechanism.

[0005] Furthermore, the joint injection mechanism includes a guide tube, a first slider module, a pusher clamp, and a push rod, with the push rod disposed inside the pusher clamp; The pusher includes a claw arm and a rotating motor. A positioning post is provided on the claw arm, and a detection switch is provided at the front end of the positioning post. The detection switch is electrically connected to the rotating motor. The claw arm is connected to the output shaft of the rotating motor. The rotating motor is fixed on the first slider module. The push rod includes an electric cylinder and a push post. The push post is connected to the output end of the electric cylinder. The first slider module, the rotary motor, and the electric cylinder are electrically connected to the control mechanism.

[0006] Furthermore, the wire harness stripping mechanism includes a stripping frame, which is mounted on the second slider module. The stripping frame is equipped with three sets of grinding wheels, which are tangent to each other in pairs. The gap between the three sets of grinding wheels is used to place enameled wire. Each set of grinding wheels is equipped with a telescopic cylinder along the radial direction. The base of the telescopic cylinder is fixed on the stripping frame. The rotating shaft of the grinding wheel is connected to the movable end of the telescopic cylinder. The second slider module, the grinding wheels, and the telescopic cylinder are electrically connected to the control mechanism.

[0007] Furthermore, the coil winding mechanism includes a lead arm, a winding arm, and a third slider module. The lead arm and the winding arm are respectively fixed on the third slider module. The lead arm includes a wire clamp and an L-shaped rod. The wire clamp is disposed at the end of the L-shaped rod. The winding arm includes a rotating arm, a winding motor, a swing arm, and an adjusting screw. One end of the rotating arm is connected to the output shaft of the winding motor. The swing arm is slidably connected to the rotating arm. The adjusting screw is disposed on the rotating arm and is connected to the rotating arm bearing. The adjusting screw passes through the swing arm and is threadedly connected to the swing arm. The end of the adjusting screw is connected to the adjusting motor. The end of the swing arm is provided with a planetary arm, which includes a swing motor, a self-rotating motor and a guide nozzle. The swing motor is used to drive the guide nozzle to swing at a certain angle, and the self-rotating motor is used to drive the guide nozzle to rotate. The swing arm has a hollow structure with an internal channel for passing through the enameled wire; the enameled wire extends out of the guide nozzle through this channel. The third slider module, the winding motor, the pitch-adjusting motor, the oscillating motor, and the self-rotating motor are electrically connected to the control mechanism.

[0008] Furthermore, the rotating arm is provided with a V-groove, and the end of the swing arm is provided with a V-shaped platform, the V-shaped platform and the V-groove are slidably engaged; the wire clamp is a pneumatic gripper, and the wire clamp is electrically connected to the control mechanism.

[0009] Furthermore, the iron core clamping mechanism includes an electromagnet and a positioning pin, and the electromagnet is electrically connected to the control mechanism.

[0010] Furthermore, the core clamping mechanism also includes a pair of V-blocks and a clamping cylinder, with the electromagnet embedded in one of the V-blocks; the pair of V-blocks are arranged opposite to each other, one of which is fixed to the frame and the other is connected to the piston rod of the clamping cylinder, and the clamping cylinder drives the V-blocks to open and close, so as to radially clamp or release the coil core.

[0011] Furthermore, the glue-dispensing mechanism includes a glue tank, a metering pump, a dispensing head, and a three-dimensional moving module. The inlet of the metering pump is connected to the glue tank via a pipe, and the outlet is connected to the dispensing head. The dispensing head is fixedly installed on the movable end of the three-dimensional moving module and is driven by the three-dimensional moving module to move precisely to the glue-dispensing port of the coil core. The metering pump and the three-dimensional moving module are electrically connected to the control mechanism.

[0012] Furthermore, the welding mechanism is a laser welding machine, which includes a laser generator, a galvanometer scanning head, and a vision positioning camera; the vision positioning camera is electrically connected to the control mechanism and is used to identify the relative position of the wire harness lead wire and the connector, and to feed back the position information to the control mechanism, which then adjusts the welding path of the galvanometer scanning head.

[0013] Secondly, this application also provides a method for processing magnetorheological coils for vibration dampers, comprising the following steps: Step S1: Core feeding and clamping. Place the coil core in the predetermined position of the core clamping mechanism so that it cooperates with the positioning post for initial positioning. The control mechanism starts the electromagnet to generate magnetic force to attract and fix the core axially. At the same time, control the clamping cylinder to drive a pair of V-blocks to hug the coil core radially, achieving reliable fixation in both the axial and radial directions. Step S2: Connector Pressing. After the iron core is clamped, the connector pressing mechanism starts working. The connector harness is placed on the guide tube, and the push clamp holds the connector. The first slider module drives the push clamp forward, so that the positioning post on the claw arm of the push clamp matches the corresponding hole on the coil iron core. If the positioning post does not match the corresponding hole on the iron core, the detection switch at the front end of the positioning post does not detect the position signal. Then the control mechanism outputs a rotation signal, and the rotation motor drives the claw arm to rotate at an angle to align the connector with the corresponding position on the coil iron core. After the detection switch detects the position signal, the control mechanism outputs a top pressure signal to control the electric cylinder to move forward and push the top post forward, finally pressing the connector into and fastening it to the predetermined depth of the coil iron core. Step S3: Stripping the wire harness end. Control the telescopic cylinder to drive the three sets of grinding wheels to feed radially in sync, feeding the wire harness end of the enameled wire into the gap between the three sets of grinding wheels of the wire harness stripping mechanism and clamping it from all sides. Start the grinding wheel to rotate and grind the insulation layer of the wire harness end; at the same time, drive the stripping frame to move a predetermined distance along the axis through the second slider module to remove the specified length of insulation layer and expose the metal wire. Step S4: Wire harness and connector winding. After stripping the wire harness end, clamp and fix it with the wire clamp of the coil winding mechanism's pull arm, pull the wire harness end to the position of the connector terminal. Adjust the swing arm to the position of the connector terminal axis by the pitch motor, swing the guide nozzle to a certain angle by the swing motor so that the outlet position of the guide nozzle and the outlet position of the swing arm form a certain angle. Then rotate the guide nozzle by the self-rotating motor to wind the enameled wire in the guide nozzle onto the connector terminal. After winding a fixed number of turns, swing the axis of the guide nozzle to the axis position of the swing arm by the swing motor to complete the wire harness and connector winding. Step S5: Welding the wire harness to the connector. After the wire harness and connector are wound together, the visual positioning camera of the welding mechanism takes pictures and identifies the relative position of the wire harness lead wire and the connector, and feeds the position information back to the control mechanism. The control mechanism calibrates the path according to the visual information, starts the laser generator and emits a laser beam through the galvanometer scanning head, and accurately welds the wire harness lead wire to the connector. Step S6: Coil winding. With the wire harness already welded to the connector, start the pitch adjustment motor and adjust the swing arm to the outside of the coil core. Then, use the third slider module to move the swing arm forward a certain distance, aligning it with the wire slot of the coil core. The control mechanism, according to the preset number of coil turns and layers, drives the winding motor to rotate the arm clockwise for winding. Simultaneously, the third slider module moves forward to arrange the wire. After winding one slot, stop winding and move the third slider module forward a distance to align the swing arm with another slot. The winding motor then drives the arm to rotate counterclockwise for winding. Simultaneously, the third slider module moves forward to arrange the wire. After winding the second slot, stop winding. After winding is complete, retract the swing arm to the other terminal axis position of the connector. Step S7: Stripping the wire harness mid-end. Control the telescopic cylinder to drive the three sets of grinding wheels to feed radially in sync. Feed the mid-end of the enameled wire harness into the gap between the three sets of grinding wheels of the wire harness stripping mechanism and clamp it from all sides. Start the grinding wheel to rotate and grind the insulation layer at the end of the wire harness. At the same time, drive the stripping frame to move a predetermined distance along the axis through the second slider module to remove the specified length of insulation layer and expose the metal wire. Step S8: The wire harness is wound around another connector. After the wire harness is stripped at the middle end, the pitch motor adjusts the swing arm to the position of the other terminal axis of the connector. The swivel motor swings the guide nozzle by a certain angle so that the outlet position of the guide nozzle and the outlet position of the swing arm form a certain angle. Then, the self-rotating motor rotates the guide nozzle to wind the enameled wire in the guide nozzle around the connector terminal. After winding a fixed number of turns, the swivel motor swings the axis of the guide nozzle to the axis position of the swing arm to complete the winding of the wire harness and the connector. Step S9: Welding the wire harness to another connector. After the wire harness is wound around the other connector, the visual positioning camera of the welding mechanism takes pictures and identifies the relative position of the wire harness lead wire and the connector, and feeds the position information back to the control mechanism. The control mechanism calibrates the path according to the visual information, starts the laser generator and emits a laser beam through the galvanometer scanning head, and accurately welds the wire harness lead wire to the connector. Step S10: Coil potting and curing. The three-dimensional moving module of the potting mechanism drives the injection head to precisely move above the potting port of the coil core with the connector already pressed in; the metering pump is started to draw a fixed amount of adhesive from the adhesive tank and inject it into the coil at a uniform speed through the injection head; after potting, the core is kept still for a period of time, or it is moved to the curing area by a conveying mechanism, allowing the adhesive to cure naturally or by heating, ultimately forming a complete magnetorheological coil product.

[0014] Compared with the prior art, the beneficial effects of this application are as follows: 1. This application provides a magnetorheological coil processing device for vibration dampers. This device integrates multiple processes such as core clamping, joint injection, wire harness stripping, coil winding, welding, and glue filling on a single frame, reducing the transfer time of the workpiece between different processes and significantly improving processing efficiency.

[0015] 2. This application provides a magnetorheological coil processing device for vibration dampers. In this application, the coil winding mechanism adopts a combination of a lead arm and a winding arm. Through the precise adjustment of the pitch screw and planetary arm, the coil winding is ensured to be uniform, avoiding problems such as uneven tension and misalignment that occur in traditional manual winding.

[0016] 3. This application provides a magnetorheological coil processing device for vibration dampers. The wire harness stripping mechanism of this application adopts a three-set tangential grinding wheel design, which can simultaneously strip the enameled wire from multiple angles, thereby improving the stripping efficiency and uniformity. Attached Figure Description

[0017] Figure 1 This is a three-dimensional structural diagram of the present application; Figure 2 This is a schematic diagram of the equiaxed structure of this application; Figure 3 This is the main view of this application; Figure 4 This is the left view of this application; Figure 5 This is the right view of this application; Figure 6 This is a top view of this application; Figure 7 This is a perspective view of the winding mechanism of this application; Figure 8 This is a front view of the winding mechanism of this application; Figure 9This is a three-dimensional view of the injection mechanism in this application; Figure 10 This is a front view of the injection mechanism in this application; Figure 11 for Figure 3 Sectional view along section AA; Figure 12 for Figure 3 Sectional view along section BB; Figure 13 for Figure 3 Sectional view along the CC section; Figure 14 for Figure 4 Sectional view along the DD section; Figure 15 for Figure 2 Enlarged view of a portion of region E in the middle; Figure 16 for Figure 5 Enlarged view of a portion of region F in the middle; Figure 17 for Figure 8 Enlarged view of a portion of region G in the middle; Figure 18 This is a diagram of the core structure of this application; Figure 19 This is a structural diagram of the connector in this application; Figure 20 This is a flowchart of the processing method for this application.

[0018] In the diagram, 1. Frame; 2. Iron core clamping structure; 21. Electromagnet; 22. Positioning pin; 23. V-block; 24. Clamping cylinder; 3. Joint injection mechanism; 31. Guide tube; 32. First slider module; 321. First slide rail; 322. Second slider; 323. Hanging rod; 33. Push clamp; 331. Claw arm; 332. Rotary motor; 333. Positioning column; 334. Detection switch; 335. Clamping plate; 336. Drive cylinder; 34. Push rod; 341. Electric cylinder; 342. Push column; 4. Wire harness stripping mechanism; 41. Stripping frame; 42. Second slider module; 43. Grinding wheel; 45. Telescopic cylinder; 5. Coil winding mechanism, 51. Lead arm, 511. Wire clamp, 512. L-bar, 52. Winding arm, 521. Rotating arm, 522. Winding motor, 523. Swing arm, 524. Adjustable pitch screw, 525. Adjustable pitch motor, 526. V-groove, 527. V-table, 528. Planetary arm, 529. Swing motor, 530. Rotating motor, 531. Guide nozzle, 53. Third slider module, 6. Welding mechanism, 61. Laser generator, 62. Galvanometer scanning head, 63. Visual positioning camera, 7. Glue dispensing mechanism, 71. Glue box, 72. Dosing pump, 73. Glue dispensing head, 74. Three-dimensional moving module, 8. Control mechanism. Detailed Implementation

[0019] The present application will be further described in detail below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solutions of the present application. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present application.

[0020] Example 1 like Figures 1 to 19 As shown, this application provides a magnetorheological coil processing device for vibration dampers, comprising: a frame 1 for support; a core clamping mechanism 2, mounted on the frame 1, for clamping the coil core; a connector injection mechanism 3, mounted on the frame 1, for injecting the connector into the coil core; a wire harness stripping mechanism 4, mounted on the frame 1, for stripping the wire harness insulation layer; a coil winding mechanism 5, mounted on the frame 1, for winding the coil; a welding mechanism 6, mounted on the frame 1, for welding the wire harness leads; a glue-filling mechanism 7, mounted on the frame 1, for filling the coil with glue; and a control mechanism 8, mounted on the frame 1, electrically connected to the core clamping mechanism 2, the connector injection mechanism 3, the wire harness stripping mechanism 4, the coil winding mechanism 5, the welding mechanism 6, and the glue-filling mechanism 7.

[0021] The connector injection mechanism 3 is responsible for precisely pressing the electrical connector into the predetermined hole of the iron core. It includes a guide tube 31, a first slider module 32, a pusher clamp 33, and a push rod 34. The push rod 34 is located inside the pusher clamp 33. The first slider module 32 includes a first slide rail 321, a first slider 322, and a hanger rod 323. The first slider 322 is slidably connected to the first slide rail 321, and the hanger rod 323 is slidably connected to the first slider 322. A drive motor is provided between the first slider 322 and the first slide rail 321 and between the first slider 322 and the hanger rod 323, respectively, for driving the first slider 322 to move laterally along the first slide rail 321 and driving the hanger rod 323 to move longitudinally along the first slider 322. The pusher clamp 33 is located at the end of the guide tube 31. The pusher clamp 33 includes a claw arm 331 and a rotating motor 332. The rotating motor 332 is fixed on the lifting rod 323. The output end of the rotating motor 332 is connected to the head end of the guide tube 31 to drive the guide tube 31 to rotate. The claw arm 331 includes a clamping plate 335 and a driving cylinder 336. The clamping plate 335 is fixed to the movable end of the driving cylinder 336. The driving cylinder 336 is fixed on the guide tube 31. A positioning post 333 is provided at the end of the guide tube 31. A detection switch 334 is provided on the positioning post 333. The detection switch 334 is electrically connected to the rotating motor 332. The rotating motor 332 is fixed on the first slider module 32. The push rod 34 includes an electric cylinder 341 and a push column 342. The electric cylinder 341 is fixed inside the head end of the guide tube 31. The push column 342 is connected to the output end of the electric cylinder 341. The first slider module 32, the rotating motor 332, the drive cylinder 336, the electric cylinder 341, and the detection switch 334 are electrically connected to the control mechanism 8.

[0022] The first slider module 32 moves the push clamp 33 holding the connector to a position approximately above the iron core. The lifting rod 323 drives the push clamp 33 to descend, causing the positioning pin 333 to attempt to mate with the connector mounting hole on the iron core. There are two sets of positioning pins 333. If the angle is off, the positioning pin 333 cannot be inserted, and the detection switch 334 at its front end will not be triggered. At this time, the control mechanism 8 will control the rotary motor 332 to drive the entire guide tube 31 and the push clamp 33 to rotate an angle until the positioning pin 333 is successfully inserted into the hole, and the detection switch 334 sends a positioning signal. Then, the control mechanism 8 commands the electric cylinder 341 to act, and the top pin 342 pushes forward, pushing the connector out of the push clamp 33 and finally pressing it into the iron core hole to the preset depth to complete the fastening. After completion, all components are reset. In this embodiment, the detection switch 334 can be a push-button switch, a pressure switch, or a Hall effect detection switch, used to detect the relative position of the positioning post 333 and the mounting hole on the iron core. For example, a push-button switch is provided at the end of the positioning post 333. If either of the two sets does not correspond to the mounting hole, the positioning post cannot be inserted into the mounting hole, and the push-button switch or pressure switch will send a pressing signal. The rotating motor 332 will then drive the guide tube 31 to rotate. When the rotation reaches the position corresponding to the two mounting holes, the push-button switch or pressure switch will release, sending a position detection signal. The rotating motor 332 will stop rotating, and at this time, the electric cylinder 341 will be driven to press the connector against the predetermined hole, completing the connector injection. If the detection switch 334 is a Hall effect switch, a sensing element is provided in the mounting hole. The working principle of the Hall effect switch is similar to that of the push-button switch or pressure switch, and will not be described in detail here.

[0023] The wire harness stripping mechanism 4 includes a stripping frame 41 mounted on a second slider module 42. Three sets of grinding wheels 43 are mounted on the stripping frame 41, with each set of grinding wheels 43 tangent to the others. The gaps between the grinding wheels 43 are used to hold the enameled wire. Each set of grinding wheels 43 has a radially mounted telescopic cylinder 45. The base of the telescopic cylinder 45 is fixed to the stripping frame 41, and the shaft of the grinding wheel 43 is connected to the movable end of the telescopic cylinder 45. The second slider module 42, the grinding wheels 43, and the telescopic cylinder 45 are electrically connected to the control mechanism 8. During this process, the grinding action of the grinding wheels 43 completely removes the insulating varnish layer within the moving range, exposing the internal metal wire. This three-point radial clamping grinding method results in uniform stripping, high efficiency, and minimal damage to the internal wire.

[0024] The coil winding mechanism 5 is the core of the coil winding process, including a lead arm 51, a winding arm 52, and a third slider module 53. The lead arm 51 and the winding arm 52 are respectively fixed on the third slider module 53. The lead arm 51 includes a wire clamp 511 and an L-shaped rod 512. The wire clamp 511 is located at the end of the L-shaped rod 512. The winding arm 52 includes a rotating arm 521, a winding motor 522, a swing arm 523, and an adjusting screw 524. One end of the rotating arm 521 is connected to the output shaft of the winding motor 522. The swing arm 523 is slidably connected to the rotating arm 521. The adjusting screw 524 is mounted on the rotating arm 521 and is connected to the rotating arm 521 by a bearing. The adjusting screw 524 passes through the swing arm. On 523, the adjusting screw 524 is threadedly connected to the swing arm 523, and the end of the adjusting screw 524 is connected to the adjusting motor 525; the end of the swing arm 523 is provided with a planetary arm 528, which includes a swing motor 529, a self-rotating motor 530 and a guide nozzle 531. The swing motor 529 is used to drive the guide nozzle 531 at a certain angle, and the self-rotating motor 530 is used to drive the guide nozzle 531 to rotate; the swing arm 523 has a hollow structure with a channel formed inside for passing through the enameled wire; the enameled wire extends out of the guide nozzle 531 through the channel; the third slider module 53, the winding motor 522, the adjusting motor 525, the swing motor 529, and the self-rotating motor 530 are respectively electrically connected to the control mechanism 8.

[0025] In this embodiment, the operation of the coil winding mechanism 5 is divided into two main stages: First, winding with the connector: The wire clamp 511 (such as a pneumatic gripper) of the lead arm 51 clamps and fixes the end of the enameled wire leading from the spool. After stripping the wire end, the lead arm 51 sends it to the vicinity of the connector terminal. The pitch motor 525 adjusts the swing arm 523 so that the guide nozzle 531 is aligned with the axis of the terminal. The swing motor 529 drives the guide nozzle 531 to swing at a certain angle so that the direction of the enameled wire exit is at a certain angle with the terminal. Then the self-rotating motor 530 drives the guide nozzle 531 to rotate several times, tightly winding the enameled wire around the terminal, completing the mechanical fixation; Second, core winding: After completing the winding at one end, the swing motor 529 resets the guide nozzle 531 to be coaxial with the swing arm 523. The pitch motor 525 adjusts the swing arm 523 to an appropriate position outside the core wire slot. According to a preset program, the control mechanism 8 controls the winding motor 522 to drive the rotating arm 521 to rotate (e.g., clockwise first), while the third slider module 53 drives the entire winding arm 52 to move at a constant speed along the iron core axis, achieving tight and neat winding of the enameled wire in the wire slot. After completing the winding of one layer or one wire slot, the winding direction can be changed (counterclockwise) to wind the next layer or the next wire slot until the predetermined number of turns is reached. During the winding process, the tension of the enameled wire can be controlled by a tensioner (not shown in the figure). In this application, the lead arm 51 adopts a movable structure, which can be a slider or lead screw structure. After the wire harness is led, the lead arm 51 is moved to a fixed position to prevent the lead arm 51 from interfering with the winding arm 52.

[0026] The rotating arm 521 is provided with a V-groove 526, and the end of the swing arm 523 is provided with a V-shaped platform 527, which is slidably engaged with the V-groove 526; the wire clamp 511 is a pneumatic gripper, and the wire clamp 511 is electrically connected to the control mechanism 8.

[0027] The core clamping mechanism 2 includes an electromagnet 21 and a positioning pin 22, with the electromagnet 21 electrically connected to the control mechanism 8. The core clamping mechanism 2 also includes a pair of V-blocks 23 and a clamping cylinder 24. One V-block 23 is fixed to the frame 1, and the other V-block 23 is connected to the piston rod of the clamping cylinder 24. During operation, the operator or robot places the coil core into the V-groove of the fixed V-block 23, ensuring its end engages with the pre-set positioning pin 22 for initial positioning. Subsequently, the control mechanism 8 issues a command to energize the electromagnet 21, generating a strong magnetic force to axially attract and fix the core, preventing axial movement. Simultaneously, it controls the clamping cylinder 24 to move the movable V-block 23 towards the fixed V-block 23, radially clamping the core. This combination of electromagnetic attraction and mechanical V-block clamping achieves reliable axial and radial fixation of the core, providing a stable and precise reference for all subsequent processing steps.

[0028] The glue-dispensing mechanism 7 includes a glue tank 71, a metering pump 72, a glue dispensing head 73, a three-dimensional moving module 74, molds 75, and a lifting cylinder 76. Two sets of molds 75 are used to clamp the coil core. One set of molds 75 is located at the movable end of the lifting cylinder 76. The glue tank 71 is mounted on the other mold 75 and fixedly connected to the three-dimensional moving module 74, which drives it to move precisely to the glue-dispensing port of the coil core. The inlet of the metering pump 72 is connected to the glue tank 71 via a pipe, and the outlet is connected to the glue dispensing head 73. The metering pump 72, the three-dimensional moving module 74, and the lifting cylinder 76 are electrically connected to the control mechanism 8. In this embodiment, the lifting cylinder 76 can be an electric cylinder or a hydraulic cylinder, used to drive the set of molds 75 to move up and down.

[0029] The welding mechanism 6 is a laser welding machine, which includes a laser generator 61, a galvanometer scanning head 62, and a vision positioning camera 63. The vision positioning camera 63 is electrically connected to the control mechanism 8 and is used to identify the relative position of the wire harness lead wire and the connector, and to feed back the position information to the control mechanism 8, which then adjusts the welding path of the galvanometer scanning head 62. In this embodiment, the welding mechanism 6 is mounted on a movable slider, which is slidably connected to a first slide rail 321. The welding mechanism 6 and the connector injection mechanism 3 are respectively located at both ends of the first slide rail 321. After the connector injection mechanism 3 completes the injection operation, it returns to the starting position. The control mechanism 8 drives the welding mechanism 6 to a fixed position to perform welding operations on the connector wire harness. After completing the welding operation, it returns to the starting position.

[0030] The control mechanism 8 is a typical industrial automation control system, serving as the brain of the device described in this application. It is typically an industrial computer (PLC or industrial PC) combined with a touchscreen human-machine interface. Internally, it stores processing programs for products of different specifications, receives signals from various sensors (such as detection switch 334 and vision camera 63), and sends control commands to various actuators (motors, cylinders, electromagnets, lasers, etc.). It is responsible for coordinating, scheduling, and controlling the action sequence, timing, position, speed, and process parameters of all actuators in the device, ensuring the entire processing flow is automated, precise, and continuous. PLCs, due to their high reliability and strong anti-interference capabilities, are suitable for this type of industrial environment. It is responsible for performing logic control, sequential control, timing, counting, and arithmetic operations. It can be integrated into the main controller or used as a standalone module. It is used to control servo motors or stepper motors in multiple slider modules (first, second, and third slider modules, three-dimensional moving modules) to achieve high-precision multi-axis point-to-point motion, linear interpolation, and speed control. Digital input / output module: Used to receive digital signals from various sensors (such as detection switch 334, limit switch, cylinder magnetic switch, electromagnet status feedback) and issue commands to control the switching of actuators (such as various drive motors, rotary motors, clamping cylinder 24, drive cylinder 336, electromagnet 21, wire clamp 511, laser generator 61 enable, etc.). Analog input / output module (optional): Used to process analog signals, such as receiving signals from tension sensors to adjust winding tension in real time, or sending speed commands to the frequency converter to precisely control the rotational speed of grinding wheel 43.

[0031] Example 2 like Figure 20 As shown, this application also provides a method for processing magnetorheological coils for vibration dampers, including the following steps: Step S1: Core feeding and clamping. The coil core is placed in the predetermined position of the core clamping mechanism 2, so that it cooperates with the positioning post 22 for initial positioning. The control mechanism 8 starts the electromagnet 21 to generate magnetic force to attract and fix the core axially. At the same time, the clamping cylinder 24 is controlled to drive a pair of V-blocks 23 to hug the coil core radially, so as to achieve reliable fixation in both the axial and radial directions. Step S2, connector injection: After the iron core is clamped, the connector injection mechanism 3 starts to work. Under the action of the first slider module 32, the first slider 322 moves laterally along the first slide rail 321, driving the lifting rod 323 to move longitudinally along the first slider 322. The connector harness is placed on the guide tube 31, the push clamp 33 holds the connector, and the lifting rod 323 drives the push clamp 33 to move forward, so that the positioning post 333 on the claw arm 331 of the push clamp 33 matches the corresponding hole on the coil iron core. If the positioning post 333 does not correspond to the corresponding hole on the iron core, the detection switch 334 at the front end of the positioning post 333 does not detect the position signal. Then the control mechanism 8 outputs a rotation signal, and the rotation motor 332 drives the claw arm 331 to rotate an angle to align the connector with the corresponding position of the coil iron core. After the detection switch 334 detects the position signal, the control mechanism 8 outputs a top pressure signal to control the electric cylinder 341 to move forward and push the top post 342 forward, finally pressing the connector into and fastening it to the predetermined depth of the coil iron core. Step S3: Stripping the wire harness end. Control the telescopic cylinder 45 to drive the three sets of grinding wheels 43 to feed radially in sync, feeding the wire harness end of the enameled wire into the gap between the three sets of grinding wheels 43 of the wire harness stripping mechanism 4 and clamping it from all sides. Start the grinding wheel 43 to rotate and grind the insulation layer of the wire harness end; at the same time, drive the stripping frame 41 to move a predetermined distance along the axis through the second slider module 42 to remove the insulation layer of a specified length and expose the metal wire. Step S4: Wire harness and connector winding. After the wire harness end is stripped, it is clamped and fixed by the wire clamp 511 of the wire arm 51 of the coil winding mechanism 5, and the wire harness end is pulled to the position of the connector terminal. The swing arm 523 is adjusted to the position of the connector terminal axis by the pitch motor 525. The guide nozzle 531 is swung 90 degrees by the swing motor 529 so that the outlet position of the guide nozzle 531 and the outlet position of the swing arm 523 form a 90-degree angle. Then the guide nozzle 531 is rotated by the self-rotation motor 530, and the enameled wire in the guide nozzle 531 is wound around the connector terminal. After winding a fixed number of turns, the axis of the guide nozzle 531 is swung to the axis position of the swing arm 523 by the swing motor 529, and the wire harness and connector winding is completed. Step S5: Welding the wire harness to the connector. After the wire harness and connector are wound together, the visual positioning camera 63 of the welding mechanism 6 takes pictures and identifies the relative position of the wire harness lead wire and the connector, and feeds back the position information to the control mechanism 8. The control mechanism 8 calibrates the path according to the visual information, starts the laser generator 61 and emits a laser beam through the galvanometer scanning head 62 to accurately weld the wire harness lead wire to the connector. Step S6: Coil winding. With the wire harness already welded to the connector, start the pitch adjustment motor 525, adjust the swing arm 523 to the outside of the coil core, and then move the swing arm 523 forward a certain distance via the third slider module 53 to align it with the wire slot of the coil core. The control mechanism 8, according to the preset number of coil turns and layers, drives the winding motor 522 to rotate the rotating arm 521 clockwise for winding. Simultaneously, the third slider module 53 moves forward to arrange the wire. After winding one slot, stop winding and move the third slider module 53 forward a distance to align the swing arm 523 with another slot. The winding motor 522 then drives the rotating arm 521 counterclockwise for winding. Simultaneously, the third slider module 53 moves forward to arrange the wire. After winding the second slot, stop winding. After winding, retract the swing arm 523 to the other terminal axis position of the connector. Step S7: Stripping the wire harness mid-end. Control the telescopic cylinder 45 to move, drive the three sets of grinding wheels 43 to feed radially in sync, feed the mid-end of the enameled wire harness into the gap between the three sets of grinding wheels 43 of the wire harness stripping mechanism 4 and clamp it from all sides, start the grinding wheel 43 to rotate and grind the insulation layer at the end of the wire harness; at the same time, drive the stripping frame 41 to move a predetermined distance along the axis through the second slider module 42 to remove the insulation layer of a specified length and expose the metal wire. Step S8: The wire harness is wound around another connector. After the wire harness is stripped at the middle end, the pitch motor 525 adjusts the swing arm 523 to the position of the other terminal axis of the connector. The swing motor 529 swings the guide nozzle 531 by a certain angle so that the outlet position of the guide nozzle 531 and the outlet position of the swing arm 523 form a 90-degree angle. Then, the self-rotating motor 530 makes the guide nozzle 531 rotate, and the enameled wire in the guide nozzle 531 is wound around the connector terminal. After winding a fixed number of turns, the swing motor 529 swings the axis of the guide nozzle 531 to the axis position of the swing arm 523 to complete the winding of the wire harness and the connector. Step S9: Welding the wire harness to another connector. After the wire harness is wound around the other connector, the visual positioning camera 63 of the welding mechanism 6 takes pictures and identifies the relative position of the wire harness lead wire and the connector, and feeds back the position information to the control mechanism 8. The control mechanism 8 calibrates the path according to the visual information, starts the laser generator 61 and emits a laser beam through the galvanometer scanning head 62 to accurately weld the wire harness lead wire to the connector. Step S10: Coil potting and curing. The upper half of the mold 75 of the potting mechanism 7 is set on the three-dimensional moving module 74, and the lower half of the mold 75 is set on the lifting cylinder 76. The two molds 75 are driven onto the coil core and clamped. The metering pump 72 is started to draw a certain amount of glue from the glue tank 71 and inject it into the gaps inside the coil at a uniform speed through the glue injection head 73. After the potting is completed, the core is kept still for a period of time to allow the glue to cure naturally or by heating, and finally a complete magnetorheological coil product is formed.

[0032] Of course, the above embodiments are not intended to limit this application, and this application is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of this application should also fall within the protection scope of this application.

Claims

1. A magnetorheological coil processing device for shock absorber characterized in that it comprises: a rack (1) for supporting, a core clamping mechanism (2) arranged on the rack (1) for clamping the coil core; a joint injection mechanism (3) arranged on the rack (1) for injecting the joint into the coil core; a wire harness stripping mechanism (4) arranged on the rack (1) for stripping the wire harness insulation layer; a coil winding mechanism (5) arranged on the rack (1) for winding the coil; a welding mechanism (6) arranged on the rack (1) for welding the wire harness lead-out wire; a glue filling mechanism (7) arranged on the rack (1) for filling glue into the coil; and a control mechanism (8) arranged on the rack (1) and electrically connected with the core clamping mechanism (2), the joint injection mechanism (3), the wire harness stripping mechanism (4), the coil winding mechanism (5), the welding mechanism (6) and the glue filling mechanism (7) respectively.

2. The magnetorheological coil processing device for shock absorber according to claim 1, characterized in that: the joint injection mechanism (3) comprises a guide pipe (31), a first slider module (32), a push clamp (33) and a top rod (34), the top rod (34) is arranged inside the push clamp (33); the first slider module (32) comprises a first sliding rail (321), a first slider (322) and a boom (323), the first slider (322) is slidably connected with the first sliding rail (321), the boom (323) is slidably connected with the first slider (322), driving motors are arranged between the first slider (322) and the first sliding rail (321) and between the first slider (322) and the boom (323) respectively for driving the first slider (322) to move transversely along the first sliding rail (321) and driving the boom (323) to move longitudinally along the first slider (322); the push clamp (33) is arranged at the end of the guide pipe (31), the push clamp (33) comprises a claw arm (331) and a rotating motor (332), the rotating motor (332) is fixed on the boom (323), the output end of the rotating motor (332) is connected with the head end of the guide pipe (31) for driving the guide pipe (31) to rotate, the claw arm (331) comprises a clamping plate (335) and a driving cylinder (336), the clamping plate (335) is fixed on the movable end of the driving cylinder (336), the driving cylinder (336) is fixed on the guide pipe (31), the end of the guide pipe (31) is provided with a positioning column (333), a detection switch (334) is arranged on the positioning column (333), the detection switch (334) is electrically connected with the rotating motor (332), and the rotating motor (332) is fixed on the first slider module (32); the top rod (34) comprises an electric cylinder (341) and a top column (342), the electric cylinder (341) is fixed inside the head end of the guide pipe (31), and the top column (342) is connected with the output end of the electric cylinder (341). ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ The first slider module (32), the rotating motor (332), the driving cylinder (336), the electric cylinder (341), and the detection switch (334) are electrically connected with the control mechanism (8).

3. The device according to claim 1, characterized in that: The wire stripping mechanism (4) comprises a stripping frame (41), the stripping frame (41) is arranged on the second slider module (42), three groups of grinding wheels (43) are arranged on the stripping frame (41), the three groups of grinding wheels (43) are tangent to each other, the gap between the three groups of grinding wheels (43) is used for placing the enameled wire, each group of grinding wheels (43) is provided with a telescopic cylinder (45) in the radial direction, the base of the telescopic cylinder (45) is fixed on the stripping frame (41), the rotating shaft of the grinding wheel (43) is connected with the movable end of the telescopic cylinder (45), and the second slider module (42), the grinding wheel (43) and the telescopic cylinder (45) are electrically connected with the control mechanism (8) respectively.

4. The device according to claim 1, characterized in that: The coil winding mechanism (5) comprises a wire pulling arm (51), a winding arm (52) and a third slider module (53), the wire pulling arm (51) and the winding arm (52) are fixed on the third slider module (53) respectively, the wire pulling arm (51) comprises a wire clamp (511) and an L-shaped rod (512), the wire clamp (511) is arranged at the end of the L-shaped rod (512), the winding arm (52) comprises a rotating arm (521), a winding motor (522), a swing arm (523) and a distance adjusting lead screw (524), one end of the rotating arm (521) is connected with the output shaft of the winding motor (522), the swing arm (523) is slidably connected with the rotating arm (521), the distance adjusting lead screw (524) is arranged on the rotating arm (521), the distance adjusting lead screw (524) is connected with the bearing of the rotating arm (521), the distance adjusting lead screw (524) is arranged in the swing arm (523), the distance adjusting lead screw (524) is threadedly connected with the swing arm (523), and the end of the distance adjusting lead screw (524) is connected with a distance adjusting motor (525). The end of the swing arm (523) is provided with a planet arm (528), the planet arm (528) comprises a swing motor (529), a self-rotation motor (530) and a guide nozzle (531), the swing motor (529) is used for driving the guide nozzle (531) by a certain angle, and the self-rotation motor (530) is used for driving the guide nozzle (531) to rotate. The swing arm (523) is a hollow structure, and a channel for passing the enameled wire is formed in the swing arm (523); the enameled wire is stretched out from the guide nozzle (531) through the channel; The third slider module (53), the winding motor (522), the distance adjusting motor (525), the swing motor (529) and the self-rotation motor (530) are electrically connected with the control mechanism (8) respectively.

5. The device according to claim 4, characterized in that: The rotating arm (521) is provided with a V-shaped groove (526), the end of the swing arm (523) is provided with a V-shaped table (527), the V-shaped table (527) is in sliding fit with the V-shaped groove (526); the wire clamp (511) is a pneumatic clamp jaw, and the wire clamp (511) is electrically connected with the control mechanism (8).

6. The magnetorheological coil processing device for shock absorber according to claim 2, characterized in that: The iron core clamping mechanism (2) comprises an electromagnet (21) and a positioning pin (22), and the electromagnet (21) is electrically connected with the control mechanism (8).

7. The magnetorheological coil processing device for shock absorber according to claim 6, characterized in that: The iron core clamping mechanism (2) further comprises a pair of V-shaped blocks (23) and a clamping cylinder (24), one of the V-shaped blocks (23) is fixed to the rack (1), and the other is connected with the piston rod of the clamping cylinder (24) and driven by the clamping cylinder (24) to realize the opening and closing of the V-shaped blocks to tightly hold or release the coil core from the radial direction.

8. The magnetorheological coil processing device for shock absorber according to claim 1, characterized in that: The glue pouring mechanism (7) comprises a glue tank (71), a metering pump (72), a glue injection head (73), a three-dimensional movement module (74), a mold (75) and a lifting cylinder (76), the mold (75) is provided in two groups, and the two groups are used for clamping the coil core, one of the molds (75) is arranged at the movable end of the lifting cylinder (76), the glue tank (71) is arranged on the other mold (75) and fixedly connected with the three-dimensional movement module (74), and the glue tank (71) is driven by the three-dimensional movement module (74) to accurately move to the glue pouring opening of the coil core; the inlet of the metering pump (72) is connected with the glue tank (71) through a pipeline, and the outlet is connected with the glue injection head (73); the metering pump (72), the three-dimensional movement module (74) and the lifting cylinder (76) are electrically connected with the control mechanism (8) respectively.

9. The magnetorheological coil processing device for shock absorber according to claim 1, characterized in that: The welding mechanism (6) is a laser welding machine, which comprises a laser generator (61), a galvanometer scanning head (62) and a visual positioning camera (63); the visual positioning camera (63) is electrically connected with the control mechanism (8) and used for identifying the relative position of the wire harness lead-out wire and the joint and feeding back the position information to the control mechanism (8), so that the control mechanism (8) adjusts the welding path of the galvanometer scanning head (62).

10. A magnetorheological coil processing method for shock absorber, characterized by comprising the following steps: Step S1, iron core loading and clamping, placing the coil core on the predetermined position of the iron core clamping mechanism (2) to cooperate with the positioning column (22) to perform initial positioning; the control mechanism (8) starts the electromagnet (21) to generate magnetic force to axially adsorb and fix the iron core; meanwhile, the clamping cylinder (24) is controlled to drive the pair of V-shaped blocks (23) to tightly hold the coil core from the radial direction, so as to realize the double reliable fixation in the axial and radial directions. ​ Step S2, joint pressure injection, after the completion of the core clamping, the joint pressure injection mechanism (3) starts to work; under the action of the first slider module (32), the first slider (322) moves transversely along the first slide rail (321), driving the boom (323) to move longitudinally along the first slider (322); the joint wire harness is placed on the guide pipe (31), the push clamp (33) clamps the joint, the boom (323) drives the push clamp (33) to advance, so that the positioning column (333) on the claw arm (331) of the push clamp (33) matches the corresponding hole position on the coil core; if the positioning column (333) does not correspond to the corresponding hole position on the core, the detection switch (334) at the front end of the positioning column (333) does not detect the position signal, then the control mechanism (8) outputs a rotating signal, the rotating motor (332) drives the claw arm (331) to rotate an angle, aligning the joint with the corresponding position of the coil core, after the detection switch (334) detects the position signal, the control mechanism (8) outputs a pressing signal to control the electric cylinder (341) to act, pushing the jacking column (342) to advance, finally pressing the joint into the coil core at a predetermined depth and fastening it; Step S3, wire harness end peeling, control the telescopic cylinder (45) to act, drive three sets of grinding wheels (43) to feed radially synchronously respectively, send the wire harness end of the enameled wire into the gap between the three sets of grinding wheels (43) of the wire harness peeling mechanism (4) and clamp it from all around, start the grinding wheel (43) to rotate and grind the insulating layer of the wire harness end; and at the same time, drive the peeling frame (41) to move a predetermined distance along the axis through the second slider module (42) to remove the specified length of the insulating layer and expose the metal wire; Step S4, wire harness and joint winding, after the wire harness end peeling is completed, the wire harness end is clamped and fixed by the wire clamp (511) of the wire pulling arm (51) of the coil winding mechanism (5), and is pulled to the position on one side of the joint terminal post, the swing arm (523) is adjusted to the joint terminal post axis position through the distance adjusting motor (525), the guide nozzle (531) is swung 90 degrees through the swing motor (529), the outlet position of the guide nozzle (531) and the outlet position of the swing arm (523) form a 90-degree included angle, and then the guide nozzle (531) is rotated through the rotation motor (530), the enameled wire in the guide nozzle (531) is wound on the joint terminal post, after a fixed number of turns are wound, the axis of the guide nozzle (531) is swung to the axis position of the swing arm (523) through the swing motor (529), and the winding of the wire harness and the joint is completed; Step S5, wire harness and joint welding, after the winding of the wire harness and the joint is completed, the visual positioning camera (63) of the welding mechanism (6) takes a picture and identifies the relative position of the wire harness lead-out wire and the joint, and feeds back the position information to the control mechanism (8); the control mechanism (8) calibrates the path according to the visual information, starts the laser generator (61) and emits a laser beam through the galvanometer scanning head (62), and accurately welds the wire harness lead-out wire to the joint; Step S6, coil winding, the completed wiring harness and joint welding wiring harness, start the distance adjusting motor (525), adjust the swing arm (523) to the outside of the coil core, and then move the swing arm (523) forward by a certain distance through the third slider module (53) to align with the wire slot of the coil core. The control mechanism (8) drives the winding motor (522) to rotate the rotating arm (521) clockwise to wind the wire according to the preset number of turns and layers. At the same time of winding, the third slider module (53) drives the forward movement to realize the wire arrangement. After winding one wire slot, stop winding, continue to move the third slider module (53) forward by a certain distance, so that the swing arm (523) is aligned with another wire slot, and the winding motor (522) drives the rotating arm (521) to rotate counterclockwise to wind the wire. At the same time of winding, the third slider module (53) drives the forward movement to realize the wire arrangement. After winding the second wire slot, stop winding. After winding is completed, retreat the swing arm (523) to the other terminal post axis position of the joint; Step S7, stripping the middle end of the wire harness, control the action of the telescopic cylinder (45) to drive the three groups of grinding wheels (43) to feed radially synchronously, send the middle end of the enameled wire into the gap between the three groups of grinding wheels (43) of the wire harness stripping mechanism (4) and clamp it from all around, start the grinding wheel (43) to rotate and grind the insulating layer of the wire end, and at the same time, move the stripping frame (41) along the axis by a predetermined distance through the second slider module (42) to remove the specified length of the insulating layer and expose the metal wire; Step S8, winding and connecting the wire harness with another joint, after stripping the middle end of the wire harness, adjust the swing arm (523) to the other terminal post axis position of the joint by the distance adjusting motor (525), swing the guide nozzle (531) by a certain angle by the swing motor (529) to make the outlet position of the guide nozzle (531) form a 90-degree included angle with the outlet position of the swing arm (523), then rotate the guide nozzle (531) by the rotation motor (530) to wind the enameled wire in the guide nozzle (531) to the terminal post of the joint, after winding a fixed number of turns, move the axis of the guide nozzle (531) to the axis position of the swing arm (523) by the swing motor (529) to complete the winding and connecting of the wire harness with the joint; Step S9, welding the wire harness with another joint, after completing the winding and connecting of the wire harness with another joint, the visual positioning camera (63) of the welding mechanism (6) takes a picture to identify the relative position of the wire harness lead-out wire and the joint, and feeds the position information back to the control mechanism (8); the control mechanism (8) calibrates the path according to the visual information, starts the laser generator (61) and emits a laser beam through the galvanometer scanning head (62) to accurately weld the wire harness lead-out wire to the joint; Step S10, coil glue filling and curing, the upper half set of mold (75) of glue filling mechanism (7) is arranged on three-dimensional moving module (74), the lower half set of mold (75) is arranged on lifting cylinder (76), two sets of mold (75) are driven to the coil core and are clamped respectively, start metering pump (72), quantitative glue solution is extracted from glue tank (71), and is injected into the gap in the coil at uniform speed through glue injection head (73);After glue filling is completed, the core is kept stationary for a period of time, and the glue solution is naturally cured or heated and cured, and finally the complete magnetorheological coil product is formed.

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