An automatic inductor shaping machine and shaping method

Abstract

The present application relates to the technical field of inductance element production equipment, and specifically relates to an automatic inductance coil shaping machine and a shaping method. The automatic inductance coil shaping machine comprises a machine body, a left-right moving system, a front-rear moving system, an indexing mechanism and a control system; the indexing mechanism is composed of an indexing servo motor, a speed reducer, an indexing plate mounting seat, a wedge-shaped indexing plate and an indexing position sensor; the wedge angle of the wedge-shaped indexing plate, i.e. the angle of the inclined surface, is customized according to the cross-sectional shape of the coil diameter to be shaped; the wedge-shaped indexing plate is mounted on the indexing plate mounting seat; the indexing servo motor drives the wedge-shaped indexing plate to rotate along the coil positioning shaft through the speed reducer. The present application makes the shaped coil arc accurate and symmetrical, and the product quality stable, greatly reduces the labor intensity and human intervention, significantly improves the production efficiency, reduces the stress concentration in the shaping process, and reduces the damage risk to the coil insulation layer and the surface state.

Description

Technical Field

[0001] This invention relates to the field of inductor manufacturing equipment technology, specifically to an automatic inductor coil shaping machine and method for automatically and accurately shaping rectangular inductor coils into arc or sector-shaped coils. Background Technology

[0002] In the production of inductors, especially high-current, large-diameter inductor coils, it is often necessary to shape the wound rectangular coils into arcs or fan-shaped structures with certain central angles (such as 90°, 120°, 180°, etc.) to meet specific installation space and electromagnetic performance requirements. Currently, the common shaping method is to use a simple fan-shaped fixture, where the coil is manually placed on the fixture and then manually rotated or bent to plastically deform it. This method has significant drawbacks: Poor accuracy and consistency: The shaping results heavily rely on the operator's experience and strength, making it difficult to accurately control the curvature, central angle, and overall symmetry of each coil. This can easily lead to problems such as left-right asymmetry, edge distortion, and inconsistent curvature between coils, resulting in a low product qualification rate.

[0003] Limited applicability: For coils with thicker wire diameters and higher rigidity, it is difficult to apply force manually or the force may be uneven, making it impossible to effectively complete the shaping, and may even damage the coil.

[0004] Low efficiency and high labor intensity: It relies entirely on manual operation, resulting in low production efficiency and high physical requirements for operators. Summary of the Invention

[0005] The purpose of this invention is to propose an automatic inductor coil shaping machine and shaping method, which can overcome the defects of manual shaping in the prior art, such as poor accuracy, low consistency, low efficiency, difficulty in shaping coils with thick wire diameter, and reliance on worker experience.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: An automatic inductor coil shaping machine includes a machine body, a left-right moving system, a front-back moving system, an indexing mechanism, and a control system. The indexing mechanism consists of an indexing servo motor, a reducer, an indexing plate mounting base, a wedge-shaped indexing plate, and an indexing position sensor. The wedge angle (i.e., the slope angle) of the wedge-shaped indexing plate is customized according to the cross-sectional shape of the coil diameter to be shaped, ensuring that the slope of the leading edge of the wedge-shaped indexing plate matches the cross-sectional shape of the straight side of the coil when the coil is inserted and spread out. The design of the wedge-shaped indexing plate maximizes the contact area and evenly distributes stress, effectively preventing coil surface indentations, insulation layer damage, or coil twisting caused by stress concentration during the spreading and indexing process. This is key to achieving high-precision, non-destructive shaping. The wedge-shaped indexing plate is mounted on the indexing plate mounting base, which has an arc-shaped groove for the movement of the wedge-shaped indexing plate, allowing the wedge-shaped indexing plate to rotate within a certain range around its axis and be locked by a locking bolt, so that its wedge angle adapts to the cross-sectional shape of different wire diameters; the indexing servo motor drives the wedge-shaped indexing plate to rotate along the coil positioning axis through a reducer; the coil positioning axis is set on the machine body; the indexing mechanism is integrated into the front and rear moving system, and under the action of the front and rear moving system, it moves precisely along the axial direction to perform insertion, opening (indexing), servo motor rotation angle along the coil positioning axis, and reset actions; its stroke and angle are precisely controlled by the control system.

[0007] The left and right movement system is installed on the machine body table and is used to support and accurately position the coil fixture and move the coil along the left and right direction (X-axis). It mainly includes a left and right movement servo motor, a ball screw, a left and right movement platform and a left and right position sensor.

[0008] The aforementioned forward and backward moving system is installed on the machine body platform, located behind or to the side of the left and right moving system. It mainly includes a forward and backward moving servo motor, a linear guide pair, a forward and backward moving slide plate, and a forward and backward position sensor, which is used to drive the indexing mechanism to move along the forward and backward direction (Y-axis) to realize the approach and departure of the wedge-shaped indexing plate relative to the coil.

[0009] The control system is a core control unit, which includes a programmable logic controller (PLC), a touch screen, servo drives, various switches and sensors, and control software. The PLC receives the parameters set by the touch screen and the feedback signals from each sensor. Through program logic operations, it sends instructions to the three servo drives to coordinate and control the precise movement of the left and right movement system, the forward and backward movement system, and the indexing mechanism.

[0010] A shaping method for an automatic inductor coil shaping machine, the core working principle of which lies in the timing and positional coordination of the left-right movement system, the front-back movement system, and the indexing mechanism; specifically as follows: 1) Initialization and positioning: Preset parameters via touch screen, including total shaping angle, single indexing angle, and number of coil turns; after startup, the left and right moving system first precisely positions the moving platform carrying the coil to the initial working position, and the position sensor provides feedback. 2) Positioning of the forward and backward moving system: The forward and backward moving system drives the entire indexing mechanism forward, so that the tip of the wedge indexing plate is precisely aligned with the predetermined cutting point of the current winding to be shaped; 3) Perform indexing and shaping: The indexing servo motor starts, drives the wedge-shaped indexing plate to insert between the two adjacent coils, and rotates a certain angle along the coil positioning axis according to the preset "single indexing angle". The wedge-shaped surface is used to spread the two coils apart, and the indexing motor completes a precise angle increment, thereby causing plastic bending deformation in this part of the coil. 4) Reset and Cycle: After a single indexing action is completed, the indexing plate retracts, and the forward and backward movement system drives the indexing mechanism to move back a small distance (to avoid interference). Then, the left and right movement system moves the coil platform to the starting position for the next coil turn's shaping. Subsequently, the forward and backward movement system drives the indexing mechanism forward again for alignment, repeating step 3); this cycle continues until all coil turns have accumulated to the preset total shaping angle.

[0011] Throughout the process, the PLC dynamically coordinates the sequence, speed, and position of the three motion axes (left and right, forward and backward, and indexing) according to a preset algorithm to ensure that each step is precise.

[0012] The coil fixtures on the left and right moving platform can be quickly changed according to the inner diameter, height and other dimensions of different coils.

[0013] Parametric settings are achieved through a touchscreen human-machine interface (HMI). Users only need to input basic coil parameters (such as external dimensions, wire diameter, target radian angle, number of turns, etc.), and the control system can automatically calculate and allocate key parameters such as left and right movement distances and single displacement of the indexing plate, achieving "one-click" operation. When changing products, there is no need to modify the mechanical structure or the underlying logic of the PLC program; only the tooling needs to be changed and the processing parameters adjusted, greatly improving the flexibility and applicability of the equipment.

[0014] The advantages of the automatic inductor coil shaping machine and method proposed in this invention compared with existing technologies are as follows: 1. High precision and high consistency: The use of servo motors, high-precision sensors and PLC closed-loop control ensures the consistency of the indexing angle of each coil, ultimately resulting in accurate curvature and good symmetry of the shaped coil, and stable product quality.

[0015] 2. High degree of automation and improved efficiency: The entire process is automated, which greatly reduces labor intensity and human intervention, and significantly improves production efficiency.

[0016] 3. Wide range of applications: The powerful servo drive and dedicated wedge indexing plate design enable it to effectively shape coils with thicker wire diameters and higher rigidity, expanding the range of applications of the equipment.

[0017] 4. Easy to operate and highly flexible: Parametric input and modular tooling design make changeover quick and convenient, adapting to the needs of multi-variety, small-batch production.

[0018] 5. Coil Protection: The wedge-shaped indexing plate design reduces stress concentration during the forming process, lowering the risk of damage to the coil insulation and surface condition. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall three-dimensional structure of the automatic inductor coil shaping machine of the present invention.

[0020] Figure 2 This is a system structure block diagram of the automatic inductor coil shaping machine of the present invention.

[0021] Figure 3 This is a partial structural diagram of the indexing mechanism in this invention.

[0022] Figure 4 This is a schematic diagram of a rectangular inductor coil to be shaped.

[0023] Figure 5 This is a schematic diagram of an arc (fan-shaped) inductor coil after being shaped by the equipment of this invention.

[0024] In the diagram: 1. Machine body; 2. Left and right movement system; 21. Left and right movement servo motor; 22. Ball screw; 23. Left and right movement platform; 24. Position sensor; 3. Front and rear movement system; 31. Front and rear movement servo motor; 32. Linear guide pair; 33. Front and rear movement slide plate; 34. Position sensor; 4. Indexing mechanism; 41. Indexing servo motor; 42. Reducer; 43. Wedge indexing plate; 44. Indexing plate mounting base; 45. Indexing position sensor; 46. Coil positioning shaft; 5. Control system; 51. Programmable Logic Controller (PLC); 52. Touch screen (HMI); 53. Servo driver; 54. Various switch sensors; 6. Coil. Detailed Implementation

[0025] The present invention will be described in detail with reference to the accompanying drawings and specific embodiments. The left-right moving system 2, the forward-backward moving system 3 and the control system 5 in this document all adopt mature structural designs in the prior art. Only their basic components are given here, without the accompanying drawings. like Figure 1As shown, an automatic inductor coil shaping machine includes a machine body 1, a left-right moving system 3, a front-back moving system 3, an indexing mechanism 4, and a control system 5. The indexing mechanism 4 consists of an indexing servo motor 41, a reducer 42, an indexing plate mounting base 44, a wedge-shaped indexing plate 43, and an indexing position sensor 45. The wedge angle, i.e., the slope angle, of the wedge-shaped indexing plate 41 is customized according to the cross-sectional shape of the coil wire diameter to be shaped, ensuring that the slope of the leading edge of the wedge-shaped indexing plate matches the cross-sectional shape of the straight side of the coil when the wire is inserted and spread out. The design of the wedge-shaped indexing plate 43 maximizes the contact area and evenly distributes stress, effectively preventing coil surface indentations, insulation layer damage, or wire twisting caused by stress concentration during the spreading and indexing process. This achieves high precision and zero defects. The key to damage reshaping; the wedge-shaped indexing plate 43 is mounted on the indexing plate mounting base 44, which has an arc-shaped groove for the movement of the wedge-shaped indexing plate, allowing the wedge-shaped indexing plate to rotate within a certain range around its axis and be locked by a locking bolt, so that its wedge angle adapts to the cross-sectional shape of different wire diameters; the indexing servo motor drives the wedge-shaped indexing plate to rotate along the coil positioning axis through a reducer; the coil positioning axis is set on the machine body; the indexing mechanism is integrated into the front and rear moving system, and under the action of the front and rear moving system, it moves precisely along the axial direction to perform insertion, opening (indexing), servo motor rotation angle along the coil positioning axis, and reset actions; its stroke and angle are precisely controlled by the control system.

[0026] The left and right moving system 2 is installed on the table of the machine body 1 and is used to carry and accurately position the coil tooling and the coil 6 to move in the left and right direction (X axis). It mainly includes a left and right moving servo motor 21, a ball screw 22, a left and right moving platform 23 and a left and right position sensor 14.

[0027] The aforementioned forward and backward moving system 3 is installed on the machine body platform, located behind or to the side of the left and right moving system. It mainly includes a forward and backward moving servo motor 31, a linear guide pair 32, a forward and backward moving slide plate 33, and a forward and backward position sensor 34, which are used to drive the indexing mechanism 4 to move along the forward and backward direction (Y axis) to realize the approach and departure of the indexing plate (43) relative to the coil.

[0028] Control System 5: The core control unit includes a programmable logic controller (PLC) 51, a touch screen (HMI) 52, servo drives*3, various switch sensors 54, and control software; PLC 51 receives the parameters set by the touch screen 52 and the feedback signals from each sensor, and sends instructions to the three servo drives 53 through program logic operations to coordinate the precise movement of the left and right movement system 2), the forward and backward movement system 3, and the indexing mechanism 4.

[0029] Workflow summary: 1. Mount the rectangular coil to be shaped onto the special fixture on the left and right moving platform 23.

[0030] 2. Set parameters on the touchscreen 52: target sector angle (e.g., 180°), number of coil turns, wire diameter, etc.

[0031] 3. Press the start button. Move system 2 left and right to move the coil to the starting position of the first coil turn.

[0032] 4. The forward and backward moving system 3 drives the indexing mechanism 4 to move forward, so that the tip of the wedge-shaped indexing plate 43 is aligned with the gap between the first and second wire turns.

[0033] 5. The indexing mechanism 4 is activated, the wedge-shaped indexing plate 43 extends and inserts into the gap of the wire coil, the indexing motor 41 drives the wedge-shaped indexing plate 43 to rotate a certain angle along the coil positioning shaft 46, and uses its wedge-shaped surface to open the two wire coils, and then uses the indexing motor 41 to complete a precise angle increment (corresponding to a single indexing angle).

[0034] 6. The wedge-shaped indexing plate 43 retracts, and the forward and backward moving system 3 drives the indexing mechanism 4 to return to its original position. The left and right moving system 2 moves the coil to the next shaping position, such as between the second and third turns.

[0035] 7. Repeat steps 4-6 until all the coil turns have been processed and the cumulative bending of the coil reaches the preset target angle.

[0036] 8. Return each axis of the equipment to its origin, remove the shaped arc coil, and complete one work cycle.

[0037] Throughout the process, the PLC dynamically coordinates the sequence, speed, and position of the three motion axes (left and right, forward and backward, and indexing) according to a preset algorithm to ensure that each step is precise.

[0038] The coil fixtures on the left and right moving platform can be quickly changed according to the inner diameter, height and other dimensions of different coils.

[0039] Parametric settings are achieved through a touchscreen human-machine interface (HMI). Users only need to input basic coil parameters (such as external dimensions, wire diameter, target radian angle, number of turns, etc.), and the control system can automatically calculate and allocate key parameters such as left and right movement distances and single displacement of the indexing plate, achieving "one-click" operation. When changing products, there is no need to modify the mechanical structure or the underlying logic of the PLC program; only the tooling needs to be changed and the processing parameters adjusted, greatly improving the flexibility and applicability of the equipment.

[0040] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. An automatic inductor coil shaping machine, characterized in that: The automatic inductor coil shaping machine includes a machine body, a left-right moving system, a front-back moving system, an indexing mechanism, and a control system. The indexing mechanism consists of an indexing servo motor, a reducer, an indexing plate mounting base, a wedge-shaped indexing plate, and an indexing position sensor. The wedge angle, or slope angle, of the wedge-shaped indexing plate is customized according to the cross-sectional shape of the coil diameter to be shaped, ensuring that the slope of the leading edge of the wedge-shaped indexing plate matches the cross-sectional shape of the straight side of the coil when the coil is inserted and spread out. The wedge-shaped indexing plate is mounted on the indexing plate mounting base, which has features for mounting the wedge-shaped indexing plate. The moving arc-shaped groove allows the wedge-shaped indexing plate to rotate within a certain range around its axis and be locked by locking bolts, so that its wedge angle adapts to the cross-sectional shape of different wire diameters; the indexing servo motor drives the wedge-shaped indexing plate to rotate along the coil positioning axis through a reducer; the coil positioning axis is set on the machine body; the indexing mechanism is integrated into the front and rear moving system, and under the action of the front and rear moving system, it moves precisely along the axial direction to perform insertion, opening (indexing), servo motor rotation angle along the coil positioning axis, and reset actions; the stroke and angle of the reset action are precisely controlled by the control system.

2. The automatic inductor coil shaping machine as described in claim 1, characterized in that: The left and right movement system is installed on the machine body platform and is used to support and accurately position the coil tooling and move the coil in the left and right direction. It includes a left and right movement servo motor, a ball screw, a left and right movement platform and a left and right position sensor.

3. The automatic inductor coil shaping machine as described in claim 1, characterized in that: The aforementioned forward and backward moving system is mounted on the machine body platform, located behind or to the side of the left and right moving system. It includes a forward and backward moving servo motor, a linear guide pair, a forward and backward moving slide plate, and a forward and backward position sensor, which is used to drive the indexing mechanism to move in the forward and backward direction, so as to realize the approach and departure of the wedge-shaped indexing plate relative to the coil.

4. An automatic inductor coil shaping machine as described in claim 1, characterized in that: The control system is a core control unit, which includes a programmable logic controller (PLC), a touch screen, a servo driver, various switch sensors, and control software. The PLC receives the parameters set by the touch screen and the feedback signals from each sensor. Through program logic operations, it sends instructions to the servo driver to coordinate and control the precise movement of the left and right movement system, the forward and backward movement system, and the indexing mechanism.

5. A shaping method for an automatic inductor coil shaping machine as described in any one of claims 1-4, characterized in that: The core working principle of the shaping method lies in the timing and positional coordination of the left-right movement system, the forward-backward movement system, and the indexing mechanism; specifically as follows: 1) Initialization and positioning: Preset parameters via touch screen, including total shaping angle, single indexing angle, and number of coil turns; after startup, the left and right moving system first precisely positions the moving platform carrying the coil to the initial working position, and the position sensor provides feedback. 2) Positioning of the forward and backward moving system: The forward and backward moving system drives the entire indexing mechanism forward, so that the tip of the wedge indexing plate is precisely aligned with the predetermined cutting point of the current winding to be shaped; 3) Perform indexing and shaping: The indexing servo motor starts, drives the wedge-shaped indexing plate to insert between the two adjacent wire turns, and rotates a certain angle along the coil positioning axis according to the preset "single indexing angle". The wedge-shaped surface is used to spread the two wire turns apart, and the indexing motor completes a precise angle increment, thereby causing the coil to produce plastic bending deformation. 4) Reset: After a single indexing action is completed, the indexing plate retracts, the forward and backward moving system drives the indexing mechanism to move back a small distance, and then the left and right moving system moves the coil platform to the shaping start position of the next coil turn. 5) Cycle: Subsequently, the forward and backward moving system drives the indexing mechanism to move forward and align again, repeating steps 3) and 4); this cycle continues until all the wire turns have accumulated to the preset total shaping angle.

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