Rapid forming process for inductor preparation

Abstract

The invention discloses a rapid forming process for inductor preparation, and relates to the technical field of inductor preparation. An inductor preparation rapid forming process comprises the following steps that S1, a U table and a T table are manufactured through a cold press by means of magnetic powder, and a coil is manufactured through a winding machine; s2, cutting the pins of the coil; s3, a groove body is formed in the U table, the cut coil is placed in the groove body, and the protruding part of the T table is inserted into the coil; s4, the coil, the T table and the U table are tightly combined through hot pressing equipment; in the step S2; s201, using a cutting device to cut out a positioning indentation at a preset position of the pin; and S202, cutting off the pin along the positioning indentation. The pin deformation of the coil can be prevented as much as possible.

Description

Technical Field

[0001] This application relates to the technical field of inductor fabrication, and in particular to a rapid prototyping process for inductor fabrication. Background Technology

[0002] As electronic devices evolve towards higher reliability and miniaturization, the manufacturing precision and product consistency of inductors, as core passive components, have become critical requirements. Inductors typically consist of a U-shaped magnetic core (U-shaped core), a T-shaped magnetic core (T-shaped core), and a coil. Coil cutting is the core process in inductor manufacturing. The regularity and length of the coil ends after cutting directly affect the positioning and fit between the magnetic core and the coil, the uniformity of the magnetic powder filling, and the continuity of the magnetic circuit distribution, ultimately impacting the inductor's lifespan and performance. Figure 1 This is a schematic diagram of the coil structure.

[0003] Existing processes mostly employ mechanical shearing. After placing the coil in a special fixture, a moving cutting blade is used to cut the two leads of the coil to obtain a qualified finished product for subsequent processing and assembly.

[0004] However, with the above-mentioned cutting method, when the size of the coil is smaller, because the small coil uses ultra-fine copper wire with low yield strength, the extrusion shearing force during mechanical cutting is likely to exceed its bearing limit, resulting in deformation such as flattening and warping at the cutting position of the pin. This will lead to problems such as the subsequent coil end not being able to fit seamlessly with the magnetic core, gaps forming after assembly, and incomplete filling of magnetic powder. Summary of the Invention

[0005] To minimize the deformation of the coil leads, this application provides a rapid prototyping process for inductor fabrication.

[0006] The rapid prototyping process for inductor fabrication provided in this application adopts the following technical solution: A rapid prototyping process for inductor fabrication includes the following steps: S1. Use magnetic powder to manufacture U-shaped and T-shaped platforms using a cold press, and use a winding machine to manufacture coils; S2. Cut the coil leads; S3, U platform is formed into a groove, the cut coil is placed in the groove, T platform is placed on U platform, and the protruding part of T platform is inserted into the coil; S4. Use hot pressing equipment to tightly bond the coil, T-stage, and U-stage; In step S2; S201. Use a cutting device to cut positioning marks at preset positions on the pins; S202. Cut the pin along the positioning indentation.

[0007] By adopting the above technical solution, this application replaces the traditional one-time extrusion shearing with a step-by-step cutting method of first indenting and then cutting. The cutting device first forms a positioning indentation at a preset position instead of cutting, which can prevent the ultra-fine copper wire from exceeding its yield limit due to excessive stress in an instant, thereby reducing the possibility of deformation such as flattening and warping from the source. The indentation can provide a precise benchmark for cutting, thereby ensuring the consistency of the cutting length and the regularity of the ends, which can facilitate subsequent coil assembly and improve the density of magnetic powder filling and the continuity of the magnetic circuit.

[0008] Preferably, step S2 further includes S203; S203, using a correction tool to straighten the pins.

[0009] By adopting the above technical solution, the additional pin straightening step after cutting can correct the minor residual deformation that may occur during the cutting process, thereby ensuring the straightness and coplanarity of the pins and avoiding misalignment in subsequent assembly due to pin bending.

[0010] Preferably, the cutting device includes a drive mechanism connected to an elastic pressing mechanism and a cutting mechanism, the cutting mechanism being capable of cutting positioning indentations and cutting off the pins; the cutting device also includes a support platform.

[0011] By adopting the above technical solution, the coil can be placed on the carrier platform, and then the drive mechanism can move the elastic pressing mechanism and the cutting mechanism. The elastic pressing mechanism can press the pin, and the cutting mechanism can cut the positioning indentation on the pin and cut off the pin.

[0012] Preferably, the support platform includes a limiting post, a cutting groove, and a positioning groove for placing pins, which are distributed sequentially at the top.

[0013] By adopting the above technical solution, the positioning groove and the limiting post of the bearing platform form a two-way positioning, which can fix the lead and the coil body, prevent lateral and longitudinal movement during the cutting process, and ensure the accuracy of the indentation and cutting position; the cutting groove is used for lead cutting.

[0014] Preferably, the support platform is connected to a rotating power component, and a collection box is provided on one side of the support platform.

[0015] By adopting the above technical solution, the rotating power component can drive the support platform to rotate so that the cut waste material falls into the collection box.

[0016] Preferably, the driving mechanism includes a two-axis driving component, a belt-driven component connected to the two-axis driving component, and a mounting base connected to the belt-driven component. Both the cutting mechanism and the elastic pressing mechanism are connected to the mounting base.

[0017] By adopting the above technical solution, the two-axis drive component and the rotating component can realize the rotation of the mounting base, which can adjust the orientation of the cutting mechanism and the elastic pressing mechanism to ensure that the cutting action is precisely aligned with the radial direction of the lead-out foot.

[0018] Preferably, the cutting mechanism includes a sliding block, the mounting base has a sliding groove, the sliding block is slidably connected to the sliding groove, the sliding groove is also provided with a pressing spring, the two ends of the pressing spring are respectively connected to the sliding block and the mounting base; a cutting component is rotatably connected to the sliding block, and a drive swing assembly connected to the cutting component is also provided on the sliding block.

[0019] By adopting the above technical solution, the cooperation between the sliding block and the pressing spring can buffer the cutting impact force and avoid pin damage caused by rigid contact; the drive component drives the cutting piece to swing regularly to indent the pin, which can ensure that the pin is subjected to uniform force.

[0020] Preferably, the drive assembly includes a drive component connected to the mounting base and a guide block eccentrically connected to the output shaft of the drive component. The cutting component has a guide groove, and the guide block is slidably connected to the guide groove.

[0021] By adopting the above technical solution, the sliding of the eccentric guide block driven by the rotating component can be transformed into the back-and-forth swinging of the cutting component. This motion mode can ensure uniform indentation depth and smooth cutting action.

[0022] Preferably, the cutting component includes a swing arm rotatably connected to a sliding block and a blade connected to the swing arm, the blade including an arc-shaped blade at one end away from the swing arm.

[0023] By adopting the above technical solution, the oscillating arc blade can easily make uniform indentations on the two pins simultaneously.

[0024] Preferably, the elastic pressing mechanism includes a slider, the mounting base has a groove, the slider is slidably connected to the groove, a pressure spring is also provided in the groove, the two ends of the pressure spring are respectively connected to the slider and the mounting base, and a pressure rod is connected to the slider.

[0025] In summary, the present invention has at least one of the following beneficial technical effects: 1. In this application, a step-by-step cutting method of indentation followed by cutting replaces the traditional one-time extrusion shearing. The cutting device first forms a positioning indentation at a preset position instead of cutting, which can prevent the ultra-fine copper wire from exceeding its yield limit due to excessive stress in an instant, thereby reducing the possibility of deformation such as flattening and warping from the source. Indentation can provide a precise reference for cutting, thereby ensuring the consistency of the cutting length and the regularity of the ends, which can facilitate subsequent coil assembly, improve the density of magnetic powder filling and the continuity of the magnetic circuit; 2. The positioning groove and limiting post of the support platform form a two-way positioning, which can fix the lead and the coil body, prevent lateral and longitudinal movement during the cutting process, and ensure accurate indentation and cutting positions; the cutting groove is used for lead cutting. 3. The mounting base can be moved and rotated using a two-axis drive and a rotating component to adjust the orientation of the cutting mechanism and the elastic pressing mechanism, thereby ensuring that the cutting action is precisely aligned with the radial direction of the lead pin. At this time, the drive and rotating component drives the eccentric guide block to slide, causing the cutting component to swing back and forth. With the help of the two-axis drive, the swinging arc blade can easily make uniform indentations on the two pins simultaneously. Subsequently, the pin can be cut off in one go by driving the two-axis drive. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the coil structure; Figure 2 This is a schematic diagram of the overall structure of a rapid prototyping process for inductor fabrication in an embodiment of this application; Figure 3 This is a structural schematic diagram used to illustrate the support platform; Figure 4 This is a structural diagram illustrating the elastic pressing mechanism; Figure 5 It is a cross-sectional view used to illustrate the elastic pressing mechanism; Figure 6 It is a sectional view used to illustrate the cutting mechanism; Figure 7 yes Figure 6 Enlarged view of section A.

[0027] The attached diagram is labeled as follows: 1. Cutting device; 2. Drive mechanism; 21. Frame; 22. Two-axis drive component; 23. Belt drive component; 24. Mounting base; 3. Elastic pressing mechanism; 31. Slider; 32. Slide groove; 33. Compression spring; 34. Pressure rod; 4. Cutting mechanism; 41. Sliding block; 42. Sliding groove; 43. Compression spring; 44. Cutting piece; 441. Swing arm; 442. Blade body; 4421. Arc blade; 45. Drive swing assembly; 451. Drive drive component; 452. Guide block; 453. Guide groove; 5. Support platform; 51. Limiting post; 52. Cutting groove; 53. Positioning groove; 6. Rotational power component; 61. Collection box. Detailed Implementation

[0028] The present invention will be further described in detail below with reference to the accompanying drawings.

[0029] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this 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. Therefore, they should not be construed as limiting this invention.

[0030] This application discloses a rapid prototyping process for inductor fabrication. This process aims to minimize mechanical deformation of the coil leads, such as flattening, warping, and stretching.

[0031] Reference Figure 1 and Figure 2 A rapid prototyping process for inductor fabrication includes the following steps: S1. Use magnetic powder to manufacture U-shaped and T-shaped platforms using a cold press, and use a winding machine to manufacture coils; Soft magnetic alloy powder with a particle size of 50-200 micrometers is selected, dried, and impurity-removed. Then, 0.3%-0.8% (by mass) of lubricant is added, and the mixture is thoroughly mixed before being fed into a mold in a cold press. Under pressure of 80-120 MPa and room temperature, U-shaped magnetic cores (U-shaped platforms) and T-shaped magnetic cores (T-shaped platforms) are formed. Positioning steps are pre-reserved on the inner wall of the U-shaped platform. Enamelled copper wire is then wound into coils using a fully automatic winding machine, with leads of a certain length pre-reserved at both ends of the coils. The specific structures of the cold press and winding machine are existing technologies and will not be described in detail here.

[0032] S2. Trim the coil leads, specifically including: S201. Position and fix the coil so that the pin extends out. Use the cutting device 1 to reciprocate along the thickness direction of the pin at a preset position and feed the cutting to cut a positioning indentation at the preset position. S202. Cut the pin along the positioning indentation; Continue to use the cutting device 1 to cut the pins, and collect the waste material after cutting.

[0033] S203. Use a correction tool to straighten the pins.

[0034] After the lead is cut off, the coil is moved to the straightening station, where the lead is straightened using tools. The tools used are either elastic pressure rollers that roll and apply pressure along the length of the lead, or clamps that apply radial pressure to the lead. Both elastic pressure rollers and clamps are existing technologies.

[0035] The additional pin straightening step after cutting can correct any minor residual deformation that may occur during the cutting process, thereby ensuring the straightness and coplanarity of the pins and avoiding misalignment in subsequent assembly due to pin bending.

[0036] S3, U platform is formed into a groove, the cut coil is placed in the groove, T platform is placed on U platform, and the protruding part of T platform is inserted into the coil; The cut coil is embedded into the U-shaped platform through the positioning step on the inner wall of the U-shaped platform.

[0037] S4. Use hot pressing equipment to pressurize and heat the coil, T-stage and U-stage to make them tightly bonded; The coil, U-shaped platform, and T-shaped platform assembly are transferred to a hot press and kept at 120-180℃ and 20-50MPa for 10-30 minutes to bond the T-shaped platform and U-shaped platform. After curing, the coil, T-shaped platform, and U-shaped platform are naturally cooled to room temperature to achieve a tight bond.

[0038] In this application, a step-by-step cutting method of first indenting and then cutting replaces the traditional one-time extrusion shearing. The reciprocating movement of the cutting device 1 along the radial direction of the lead can form a positioning indentation at a preset position, which not only disperses the shearing force but also prevents the ultra-fine copper wire from exceeding its yield limit due to excessive instantaneous stress, thereby reducing the possibility of deformation such as flattening and warping from the root. The indentation can provide a precise reference for cutting, thereby ensuring the consistency of the cutting length and the regularity of the end, which can facilitate subsequent coil assembly and improve the density of magnetic powder filling and the continuity of the magnetic circuit.

[0039] Reference Figure 2 In order to achieve reliable pin cutting, the cutting device 1 includes a drive mechanism 2, which is connected to an elastic pressing mechanism 3 and a cutting mechanism 4. The elastic pressing mechanism 3 can press the pin to facilitate subsequent cutting, and the cutting mechanism 4 can cut positioning indentations and cut off the pin. The cutting device 1 also includes a support platform 5 for placing the coil.

[0040] Reference Figure 3 The support platform 5 includes a limiting post 51, a cutting groove 52 and a positioning groove 53 for placing pins, which are distributed sequentially at the top. The end of the positioning groove 53 away from the limiting post 51 is open. In this embodiment, there are two positioning grooves 53. Since the coil has two pins and the two pins have different heights, the heights of the two positioning grooves 53 are also different. The positioning groove 53 can limit the pins in the horizontal direction.

[0041] After the coil is placed on the limiting post 51 and the pin is placed in the positioning groove 53, both the coil and the pin will be limited to facilitate subsequent pin cutting.

[0042] Reference Figure 2 and Figure 3 To facilitate subsequent waste collection, the support platform 5 is connected to a rotating power component 6, and a collection box 61 is provided on one side of the support platform 5. The rotating power component 6 is, for example, a rotating cylinder.

[0043] After cutting, the drive rotation power component 6 drives the support platform 5 to rotate so that the waste material slides into the collection box 61 along the positioning groove 53.

[0044] Reference Figure 2 The drive mechanism 2 includes a frame 21, a two-axis drive component 22 connected to the frame 21, a belt drive component 23 connected to the two-axis drive component 22, and a mounting base 24 connected to the belt drive component 23. The two-axis drive component 22 and the belt drive component 23 can be cylinders, hydraulic cylinders, ball screw mechanisms, belt mechanisms, gear and rack mechanisms, etc. The cutting mechanism 4 and the elastic pressing mechanism 3 are both connected to the mounting base 24.

[0045] Reference Figure 4 and Figure 5 The elastic pressing mechanism 3 includes a slider 31, a mounting base 24 with a groove 32, the slider 31 is slidably connected to the groove 32, the groove 32 is vertically arranged, and a pressure spring 33 is also provided in the groove 32. The two ends of the pressure spring 33 are respectively connected to the slider 31 and the mounting base 24, and multiple pressure rods 34 are connected to the slider 31.

[0046] The driving two-axis drive unit 22 can drive multiple pressure rods 34 to press the two pins into the positioning groove 53.

[0047] Reference Figure 6 Specifically, the cutting mechanism 4 includes a sliding block 41, a sliding groove 42 on the mounting base 24, the sliding block 41 is slidably connected to the sliding groove 42, and a pressing spring 43 is also provided in the sliding groove 42. The two ends of the pressing spring 43 are respectively connected to the sliding block 41 and the wall of the sliding groove 42. A cutting piece 44 is rotatably connected to the sliding block 41, and a swinging component 45 connected to the cutting piece 44 is also provided on the sliding block 41. The swinging component 45 can drive the cutting piece 44 to swing.

[0048] Reference Figure 7 The drive assembly 45 includes a drive component 451 connected to the mounting base 24 and a guide block 452 eccentrically connected to the output shaft of the drive component 451. The drive component 451 is a motor. The cutting component 44 has a guide groove 453, which is vertically arranged. The guide block 452 is slidably connected to the guide groove 453.

[0049] After the coil is placed on the support platform 5, the dual-axis drive 22 and the rotating component 23 are driven to rotate the mounting base 24 to adjust the orientation of the cutting component 44 and the pressure rod 34, thereby ensuring that the cutting action is precisely aligned with the radial direction of the lead. The dual-axis drive 22 drives the pressure rod 34 and the cutting component 44 to move gradually. First, under the action of the pressure spring 33, the pressure rod 34 presses the two leads into the positioning groove 53. Then, the rotating component 451 drives the guide block 452 to move back and forth in the guide groove 453, thereby causing the cutting component 44 to swing. At this time, with the feed of the cutting component 44, the lead can be indented. After the indentation is completed, the rotating component 451 is stopped, and the dual-axis drive 22 drives the cutting component 44 to move to cut the lead in one go. Of course, this application can also achieve lead cutting by making the cutting component 44 swing back and forth and gradually pressing and cutting, but its cutting speed is lower than the above-mentioned indentation and one-time cutting method.

[0050] Reference Figure 6 and Figure 7 The cutting component 44 includes a swing arm 441 rotatably connected to a sliding block 41 and a blade 442 connected to the swing arm 441. The blade 442 includes an arc-shaped blade 4421 at the end away from the swing arm 441. The swinging arc-shaped blade 4421 facilitates simultaneous and uniform indentation of the two leads. Figure 2 Of course, since the two pins are at different heights, the rotating power component 6 needs to be driven to rotate at a certain angle so that the two pins are on the same horizontal plane.

[0051] The implementation principle of a rapid prototyping process for inductor fabrication in this application embodiment is as follows: By using the cutting device 1 to replace the traditional one-time extrusion shearing with a step-by-step cutting method of first indenting and then cutting, the reciprocating movement of the cutting device 1 along the radial direction of the pin can form a positioning indentation at a preset position, which not only disperses the shearing force, but also avoids the ultra-fine copper wire from exceeding the yield limit due to excessive stress in an instant, thereby reducing the possibility of deformation such as flattening, warping and stretching from the source.

[0052] The embodiments described herein are preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, all equivalent changes made in accordance with the structure, shape, and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A rapid prototyping process for inductor fabrication, characterized in that: Includes the following steps: S1. Use magnetic powder to manufacture U-shaped and T-shaped platforms using a cold press, and use a winding machine to manufacture coils; S2. Cut the coil leads; S3, U platform is formed into a groove, the cut coil is placed in the groove, T platform is placed on U platform, and the protruding part of T platform is inserted into the coil; S4. Use hot pressing equipment to tightly bond the coil, T-stage, and U-stage; In step S2; S201. Use the cutting device (1) to cut a positioning indentation at the preset position of the pin; S202. Cut the pin along the positioning indentation.

2. The rapid prototyping process for inductor fabrication according to claim 1, characterized in that: The S2 step also includes S203; S203, using a correction tool to straighten the pins.

3. The rapid prototyping process for inductor fabrication according to claim 1, characterized in that: The cutting device (1) includes a driving mechanism (2), which is connected to an elastic pressing mechanism (3) and a cutting mechanism (4). The cutting mechanism (4) is capable of cutting positioning marks and cutting off the pins on the pins. The cutting device (1) also includes a support platform (5).

4. The rapid prototyping process for inductor fabrication according to claim 3, characterized in that: The support platform (5) includes a limiting post (51), a cutting groove (52), and a positioning groove (53) for placing pins, which are distributed sequentially at the top.

5. The rapid prototyping process for inductor fabrication according to claim 4, characterized in that: The support platform (5) is connected to a rotating power component (6), and a collection box (61) is provided on one side of the support platform (5).

6. The rapid prototyping process for inductor fabrication according to claim 3, characterized in that: The drive mechanism (2) includes a two-axis drive component (22), a belt drive component (23) connected to the two-axis drive component (22), and a mounting base (24) connected to the belt drive component (23). The cutting mechanism (4) and the elastic pressing mechanism (3) are both connected to the mounting base (24).

7. The rapid prototyping process for inductor fabrication according to claim 6, characterized in that: The cutting mechanism (4) includes a sliding block (41), and a sliding groove (42) is provided on the mounting base (24). The sliding block (41) is slidably connected to the sliding groove (42). A pressing spring (43) is also provided in the sliding groove (42). The two ends of the pressing spring (43) are respectively connected to the sliding block (41) and the mounting base (24). A cutting piece (44) is rotatably connected to the sliding block (41), and a drive swing assembly (45) connected to the cutting piece (44) is also provided on the sliding block (41).

8. The rapid prototyping process for inductor fabrication according to claim 7, characterized in that: The drive assembly (45) includes a drive member (451) connected to the mounting base (24) and a guide block (452) eccentrically connected to the output shaft of the drive member (451). The cutting member (44) has a guide groove (453), and the guide block (452) is slidably connected to the guide groove (453).

9. The rapid prototyping process for inductor fabrication according to claim 7, characterized in that: The cutting component (44) includes a swing arm (441) rotatably connected to a sliding block (41) and a blade (442) connected to the swing arm (441), the blade (442) including an arc blade (4421) at one end away from the swing arm (441).

10. The rapid prototyping process for inductor fabrication according to claim 6, characterized in that: The elastic pressing mechanism (3) includes a slider (31), and a groove (32) is opened on the mounting base (24). The slider (31) is slidably connected to the groove (32). A pressure spring (33) is also provided in the groove (32). The two ends of the pressure spring (33) are respectively connected to the slider (31) and the mounting base (24). A pressure rod (34) is connected to the slider (31).

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