Rapid winding machine for opening coil of circuit breaker

Abstract

The invention relates to the technical field of opening coil winding, in particular to a rapid winding machine for a breaker opening coil, which comprises a rectangular frame, a speed reducer, a winding motor, a copper wire winding drum, an unwinding motor, a positioning roller, a tensioning roller, an adjusting roller, a wiring mechanism and an electric control monitoring mechanism, a rectangular inner core to be wound is fixedly installed at the output shaft end of the speed reducer and rotates along with the speed reducer to be wound, the unwinding motor drives the copper wire winding drum to unwind copper wires, and the copper wires sequentially wind around the positioning roller, the tensioning roller and the adjusting roller and then are fixedly connected with the rectangular inner core. The fixed sliding block synchronously rotates along with the speed reducer, the follow-up sliding rod and the follow-up spring are matched to drive the follow-up sliding block to be tightly attached to the rotating track of the rectangular inner core, then the transmission rod set is synchronously linked with the tensioning roller and the pressing roller to adjust the distance from the inner core, the radius difference between the corner and the plane is accurately compensated, nonlinear fluctuation of traction force is effectively restrained, and the traction efficiency is improved. The fluctuation range of traction force of the copper wire is reduced, and the conditions of tensile deformation and wire diameter reduction of the copper wire are reduced.

Description

A rapid winding machine for circuit breaker trip coils Technical Field

[0001] This invention relates to the field of circuit breaker trip coil winding technology, specifically a rapid winding machine for circuit breaker trip coils. Background Technology

[0002] In the field of circuit breakers, rectangular trip coils have significant advantages such as strong spatial adaptability, compact magnetic circuit structure, and high fit with the internal cavity of miniature molded case circuit breakers. They can effectively improve the accuracy of circuit breaker tripping action and space utilization. They have gradually replaced traditional circular trip coils and become the core actuator of miniaturized, high-precision circuit breakers, and are widely used in key scenarios such as power distribution and industrial control.

[0003] To meet the mass production needs of rectangular trip coils, a number of targeted winding equipment have emerged on the market. However, most of these equipment are based on the principle of circular coil winding and have not been fully adapted to the structural characteristics of rectangular cores. This has resulted in technical bottlenecks that are difficult to overcome during the winding process, which seriously affect the production quality and performance stability of the coils.

[0004] The distances from the corners and planar areas of the rectangular inner core to the center of rotation naturally differ. Existing equipment relies solely on a single spring tensioning mechanism to passively adjust the tension, failing to synchronously adjust the component positions according to the inner core's rotation trajectory. This causes the copper wire traction force to fluctuate non-linearly with the rotation radius, leading to copper wire stretching deformation, reduced wire diameter, and directly weakened electromagnetic force output of the trip coil, thus prolonging the tripping response time. Simultaneously, as the number of winding layers increases, the inner diameter of the coil's outer circumference gradually expands. The spring tensioning mechanism used in traditional equipment is a static tension compensation structure, unable to adapt to dynamic changes in the inner diameter. As the inner diameter expands, the spring force continuously increases, exacerbating tension fluctuations. Consequently, the tension on the copper wire increases, causing stretching deformation and affecting the uniformity of the copper wire diameter. After multi-layer winding, problems such as coil stacking and uneven winding density easily occur, ultimately affecting the coil's performance consistency and making it difficult to meet the requirements of high-precision circuit breakers for trip coils. Summary of the Invention

[0005] The purpose of this invention is to provide a rapid winding machine for circuit breaker tripping coils to solve the problems mentioned in the background art.

[0006] The objective of this invention can be achieved through the following technical solution: A rapid winding machine for circuit breaker tripping coils, preferably comprising a rectangular frame, a reducer, a winding motor, a copper wire drum, an unwinding motor, a positioning roller, a tension roller, an adjusting roller, a wiring mechanism, and an electrical control monitoring mechanism. The winding motor drives the reducer, and the rectangular inner core to be wound is fixed to the output shaft end of the reducer and rotates with it. The unwinding motor drives the copper wire drum to unwind the copper wire, which passes through the positioning roller, tension roller, and adjusting roller in sequence and is then fixed to the rectangular inner core. The machine also includes a follow-up linkage adjustment mechanism, a pressing and leveling mechanism, and a multi-layer inner diameter compensation mechanism. These three mechanisms work together to eliminate the difference in rotation radius between the corners of the rectangular inner core and the plane, and the fluctuation in the traction force of the copper wire caused by changes in the inner diameter of the multi-layer winding. The machine also includes a transmission rod assembly. The follow-up linkage adjustment mechanism is connected to the pressing and leveling mechanism and the tension roller through the transmission rod assembly. The multi-layer inner diameter compensation mechanism is assembled at the bottom of the transmission rod assembly to synchronously adapt to changes in the inner diameter and prevent the copper wire from being stretched and deformed.

[0007] Preferably, the follow-up linkage adjustment mechanism includes a pair of horizontal bars, a vertical bar, a follow-up slider, a follow-up slide rod, a fixed slider, and a follow-up spring. The vertical bar is slidably assembled between the two horizontal bars, the follow-up slider is slidably sleeved on the vertical bar, one end of the follow-up slide rod is fixedly connected to the follow-up slider, the fixed slider is fixedly connected to the end of the reducer shaft and slides in cooperation with the end of the follow-up slide rod away from the follow-up slider, and the follow-up spring is sleeved on the outer periphery of the follow-up slide rod, with its two ends abutting against the fixed slider and the follow-up slider, respectively.

[0008] Preferably, the pressing and leveling mechanism includes a pair of adjusting slide rods, a pressing roller mounting frame, a T-shaped pressing slide rod, a roller frame, a pressing roller, and a pressing spring. The two adjusting slide rods are symmetrically slidably connected inside the rectangular frame. The pressing roller mounting frame is fixedly connected to one end of the four adjusting slide rods facing the inner core of the rectangle. The T-shaped pressing slide rods symmetrically slide through the pressing roller mounting frame. The roller frame is fixedly connected to the ends of the two T-shaped pressing slide rods. The pressing roller is rotatably connected inside the roller frame. The pressing spring is sleeved on the outer periphery of the T-shaped pressing slide rod and drives the pressing roller to flexibly adhere to the copper wire.

[0009] Preferably, the transmission rod assembly consists of one transmission vertical rod and two transmission horizontal rods. The two transmission horizontal rods are respectively hinged to the T-shaped mounting rods corresponding to the pressing roller mounting frame and the tensioning roller. A pair of adjusting slide rods are symmetrically fixed to the T-shaped mounting rods. The adjusting slide rods slide in cooperation with the rectangular frame. When the follower slider moves along the rotation trajectory of the rectangular inner core, the transmission rod assembly synchronously drives the tensioning roller and the pressing roller to adjust the distance between them and the rectangular inner core.

[0010] Preferably, the installation structure of the tensioning roller includes a T-shaped tensioning slide bar, a connecting block, and a tensioning spring. The T-shaped tensioning slide bar is slidably connected to the T-shaped mounting rod, the tensioning roller is rotatably connected to the connecting block, the connecting block is fixedly connected to the T-shaped tensioning slide bar, and the tensioning spring is sleeved on the outer periphery of the T-shaped tensioning slide bar. When the tensioning roller moves along the T-shaped tensioning slide bar close to the adjusting roller, it compresses the tensioning spring to store force, thereby realizing adaptive adjustment of the copper wire tension.

[0011] Preferably, the multi-layer inner diameter compensation mechanism includes an adjustment frame, an adjustment motor, a first bevel gear, a second bevel gear, and two adjustment screws. The adjustment frame is fixed to the bottom of the transmission rod, the adjustment motor is fixed to the outside of the adjustment frame, and its output end is fixed to the second bevel gear. The two adjustment screws are symmetrically rotated and assembled inside the adjustment frame, one end of which extends to the outside and has an adjustment screw groove, and the other end is fixed to the first bevel gear. The first bevel gear meshes with the second bevel gear, and the adjustment screw groove is threaded with the corresponding transmission rod.

[0012] Preferably, the wiring mechanism includes a wiring screw, a wiring guide rod, a wiring slider, a bevel gear three, a bevel gear four, and a wiring motor disposed inside a rectangular frame. The wiring slider is slidably sleeved on the wiring guide rod. An adjusting roller is rotatably connected to one end of the wiring slider. The wiring slider is threadedly engaged with the wiring screw. The bevel gear three is fixedly connected to the shaft end of the wiring screw. The bevel gear four meshes with the bevel gear three and is fixedly connected to the output end of the wiring motor.

[0013] Preferably, the electrical control monitoring mechanism includes an L-shaped support frame fixed to the top of a rectangular frame. The L-shaped support frame is equipped with a touch screen controller and a monitoring sensor. The touch screen controller is electrically connected to the winding motor, unwinding motor, adjusting motor, and wiring motor to realize coordinated control of each component and recording of winding data.

[0014] Preferably, the fixed slider has a sliding hole, and the end of the follower slider away from the follower slider passes through the sliding hole and slides in fit. The follower spring compensates for the difference in rotation radius through elastic extension and contraction, driving the follower slider to slide bidirectionally along the vertical and horizontal bars.

[0015] Preferably, the two ends of the compression spring abut against the inner wall of the compression roller mounting frame and the roller frame, respectively, and the bonding pressure is adjusted by the pre-tightening force to avoid deformation of the copper wire cross section and damage to the paint film.

[0016] The beneficial effects of this invention are as follows: 1. This invention uses a fixed slider that rotates synchronously with the reducer. The follower slider and follower spring work together to drive the follower slider to closely fit the rotation trajectory of the rectangular inner core. Then, the transmission rod group synchronously links the tension roller and the pressing roller to adjust the distance from the inner core, accurately compensating for the radius difference between the corners and the plane, effectively suppressing the nonlinear fluctuation of the traction force, reducing the fluctuation amplitude of the copper wire traction force, reducing the occurrence of tensile deformation and shrinkage of the copper wire, and ensuring the stability of the electromagnetic force output of the trip coil and the trip response speed.

[0017] 2. This invention, through precise transmission of the motor, bevel gear set and adjusting screw, can dynamically adjust the position of the pressing roller and tensioning roller in real time according to the number of winding layers, accurately adapt to the need for increasing the inner diameter of the coil, reduce the cumulative error of multi-layer winding, and at the same time, the pressing and leveling mechanism drives the pressing roller to flexibly fit with the copper wire through the pressing spring, effectively improving the flatness of the coil winding, avoiding the stacking of wire turns, reducing magnetic leakage in the magnetic circuit, and significantly improving the consistency of coil performance.

[0018] 3. This invention uses a transmission rod assembly as a linkage carrier to achieve synchronous and coordinated action of the follow-up, tensioning, and pressing mechanisms, ensuring precise and efficient compensation and adjustment for the difference in the inner core radius and the changes in the inner diameter of multiple layers. At the same time, combined with the axial uniform arrangement of the wiring mechanism and the full-process control of electrical monitoring, it realizes automated high-precision winding of rectangular trip coils, effectively improving production efficiency. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Figure 1 is a schematic diagram of the overall structure of the rectangular frame in the present invention; Figure 2 is a top view of the rectangular frame in the present invention; Figure 3 is a front view of the rectangular frame in the present invention; Figure 4 is a side view of the rectangular frame in the present invention; Figure 5 is a schematic diagram of the installation positions of the positioning roller, tension roller, and adjusting roller in the present invention; Figure 6 is a schematic diagram of the connection relationship between the horizontal bar and the vertical bar in the present invention; Figure 7 is a schematic diagram of the connection relationship between the transmission vertical bar and the transmission horizontal bar in the present invention; Figure 8 is an exploded view of the internal structure of the transmission horizontal bar in the present invention.

[0020] The reference numerals in the diagram are as follows: 1. Rectangular frame; 2. Reducer; 3. Winding motor; 4. Copper wire drum; 5. Unwinding motor; 6. Positioning roller; 7. Tensioning roller; 8. Adjusting roller; 9. Horizontal bar; 10. Vertical bar; 11. Follower slider; 12. Follower slide bar; 13. Fixed slider; 14. Follower spring; 15. Adjusting slide bar one; 16. Pressing roller mounting frame; 17. T-shaped pressing slide bar; 18. Roller frame; 19. Pressing roller; 20. Pressing spring; 21. Transmission upright; 22. 23. Transmission horizontal rod; 24. T-shaped mounting rod; 25. Adjusting slide rod II; 26. T-shaped tensioning slide rod; 27. Connecting block; 28. Tensioning spring; 29. ​​Adjusting frame; 30. Adjusting motor; 31. Bevel gear I; 32. Bevel gear II; 33. Adjusting screw; 34. Wiring screw; 35. Wiring guide rod; 36. Wiring slider; 37. Bevel gear III; 38. Bevel gear IV; 39. Wiring motor; 40. L-shaped support frame; 41. Touch screen controller; 42. Monitoring sensor. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] A rapid winding machine for circuit breaker trip coils is disclosed. This rapid winding machine is a core piece of equipment for the production of rectangular trip coils. It is specifically designed to achieve dynamic compensation of the difference between the corner and plane radius during the winding of the rectangular inner core, adaptive adjustment of copper wire tension, and precise matching of the inner diameter of the multi-layer winding by means of the coordinated operation of a follow-up linkage adjustment mechanism, a pressing and leveling mechanism, and a multi-layer inner diameter compensation mechanism. At the same time, it completes the full-process automated control and data recording of the axial uniform arrangement of copper wires and the winding process.

[0023] As shown in Figures 1-8, the system includes a rectangular frame 1, a reducer 2, a winding motor 3, a copper wire drum 4, an unwinding motor 5, a positioning roller 6, a tension roller 7, an adjusting roller 8, a wiring mechanism, and an electrical control and monitoring mechanism. The winding motor 3 drives the reducer 2. The rectangular inner core to be wound is fixed to the output shaft end of the reducer 2 and rotates with it. The unwinding motor 5 drives the copper wire drum 4 to unwind the copper wire. The copper wire passes through the positioning roller 6, the tension roller 7, and the adjusting roller 8 in sequence before being fixed to the rectangular inner core. The circumferential cross-section of the rectangular inner core is approximately square, and the four corners of the approximately square cross-section of the rectangular inner core are rounded to reduce the flatness during rotation. The difference in rotation radius between the face and the four corners reduces the compensation load of the follow-up linkage adjustment mechanism, improving winding efficiency and stability, coil flatness, and forming effect. It also includes a follow-up linkage adjustment mechanism, a pressing and leveling mechanism, and a multi-layer inner diameter compensation mechanism. The three work together to eliminate the difference in rotation radius between the rectangular inner core corners and the plane, and the fluctuation of copper wire traction force caused by changes in the inner diameter of multi-layer winding. It also includes a transmission rod group. The follow-up linkage adjustment mechanism is connected to the pressing and leveling mechanism and the tension roller 7 through the transmission rod group. The multi-layer inner diameter compensation mechanism is assembled at the bottom of the transmission rod group to synchronously adapt to changes in inner diameter and avoid copper wire stretching and deformation.

[0024] The follow-up linkage adjustment mechanism includes a pair of horizontal bars 9, a vertical bar 10, a follow-up slider 11, a follow-up slide rod 12, a fixed slider 13, and a follow-up spring 14. The vertical bar 10 is slidably assembled between the two horizontal bars 9. The follow-up slider 11 is slidably sleeved on the vertical bar 10. One end of the follow-up slide rod 12 is fixedly connected to the follow-up slider 11. The fixed slider 13 is fixedly connected to the shaft end of the reducer 2 and slides in cooperation with the end of the follow-up slide rod 12 away from the follow-up slider 11. The follow-up spring 14 is sleeved on the outer periphery of the follow-up slide rod 12, and its two ends abut against the fixed slider 13 and the follow-up slider 11, respectively. The rotation of the fixed slider 13 drives the follow-up slide rod 12 to rotate. When the rotation radius changes, the follow-up spring 14 generates force through elastic extension and contraction, driving the follow-up slider 11 to slide up and down along the vertical bar 10, and at the same time driving the vertical bar 10 to slide horizontally along the pair of horizontal bars 9, so that the motion trajectory of the follow-up slider 11 fits with the outer periphery of the rectangular inner core, thereby realizing the compensation for the fluctuation of the basic traction force.

[0025] Furthermore, the pressing and leveling mechanism includes a pair of adjusting slide rods 15, a pressing roller mounting frame 16, a T-shaped pressing slide rod 17, a roller frame 18, a pressing roller 19, and a pressing spring 20. The two adjusting slide rods 15 are symmetrically slidably connected inside the rectangular frame 1. The pressing roller mounting frame 16 is fixedly connected to one end of the four adjusting slide rods 15 facing the inner core of the rectangle. The T-shaped pressing slide rod 17 symmetrically slides through the pressing roller mounting frame 16. The roller frame 18 is fixedly connected to the ends of the two T-shaped pressing slide rods 17. The pressing roller 19 is rotatably connected inside the roller frame 18. The pressing spring 20 is sleeved on the outer periphery of the T-shaped pressing slide rod 17 and drives the pressing roller 19 to flexibly adhere to the copper wire.

[0026] Furthermore, the transmission rod assembly consists of a transmission vertical rod 21 and two transmission horizontal rods 22. The two transmission horizontal rods 22 are respectively hinged to the T-shaped mounting rods 23 corresponding to the pressing roller mounting frame 16 and the tensioning roller 7. A pair of adjusting slide rods 24 are symmetrically fixed to the T-shaped mounting rods 23. The adjusting slide rods 24 are slidably engaged with the rectangular frame 1. When the follower slider 11 moves along the rotation trajectory of the rectangular inner core, the transmission rod assembly synchronously drives the tensioning roller 7 and the pressing roller 19 to adjust their distance from the rectangular inner core. The transmission vertical rod 21 moves with the follower slider 11, causing the two transmission horizontal rods 22 to swing synchronously, thereby driving the pressing roller mounting frame 16 to slide along the adjusting slide rod 15 and the T-shaped mounting rod 23 along the adjusting slide rod 24, so that the pressing roller 19 and the tensioning roller 7 always maintain an appropriate distance from the rectangular inner core.

[0027] Furthermore, the installation structure of the tension roller 7 includes a T-shaped tensioning slide bar 25, a connecting block 26, and a tension spring 27. The T-shaped tensioning slide bar 25 is slidably connected to the T-shaped mounting rod 23, the tension roller 7 is rotatably connected to the connecting block 26, the connecting block 26 is fixedly connected to the T-shaped tensioning slide bar 25, and the tension spring 27 is sleeved on the outer periphery of the T-shaped tensioning slide bar 25. When the tension roller 7 moves along the T-shaped tensioning slide bar 25 close to the adjusting roller 8, it squeezes the tension spring 27 to store force, thereby realizing adaptive adjustment of the copper wire tension.

[0028] Furthermore, the multi-layer inner diameter compensation mechanism includes an adjusting frame 28, an adjusting motor 29, a first bevel gear 30, a second bevel gear 31, and two adjusting screws 32. The adjusting frame 28 is fixed to the bottom of the transmission rod 21, and the adjusting motor 29 is fixed to the outside of the adjusting frame 28. Its output end is fixed to the second bevel gear 31. The two adjusting screws 32 are symmetrically rotated and assembled inside the adjusting frame 28. One end extends to the outside and has an adjusting screw groove, and the other end is fixed to the first bevel gear 30. The first bevel gear 30 meshes with the second bevel gear 31, and the adjusting screw groove is threadedly engaged with the corresponding transmission horizontal rod 22. Through the threaded engagement of the adjusting screw groove with the transmission horizontal rod 22, the pressing roller mounting frame 16 and the T-shaped mounting rod 23 are pushed to move outward along the first adjusting slide rod 15 and the second adjusting slide rod 24, expanding the inner diameter of the copper wire traction winding and ensuring that the copper wire is evenly stressed during multi-layer winding.

[0029] Furthermore, the wiring mechanism includes a wiring screw 33, a wiring guide rod 34, a wiring slider 35, a bevel gear 36, a bevel gear 4, and a wiring motor 38, all disposed inside the rectangular frame 1. The wiring slider 35 is slidably sleeved on the wiring guide rod 34. An adjusting roller 8 is rotatably connected to one end of the wiring slider 35. The wiring slider 35 is threadedly engaged with the wiring screw 33. The bevel gear 36 is fixedly connected to the shaft end of the wiring screw 33. The bevel gear 4 meshes with the bevel gear 36 and is fixedly connected to the output end of the wiring motor 38.

[0030] Furthermore, the electrical control and monitoring mechanism includes an L-shaped support frame 39 fixed to the top of the rectangular frame 1. The L-shaped support frame 39 is equipped with a touch screen controller 40 and a monitoring sensor 41. The touch screen controller 40 is electrically connected to the winding motor 3, the unwinding motor 5, the adjusting motor 29, and the wiring motor 38 to realize coordinated control of each component and recording of winding data.

[0031] Furthermore, a sliding hole is provided on the fixed slider 13, and the end of the follower slider 12 away from the follower slider 11 passes through the sliding hole and slides in fit. The follower spring 14 compensates for the difference in rotation radius through elastic extension and contraction, and drives the follower slider 11 to slide bidirectionally along the vertical rod 10 and the horizontal rod 9.

[0032] Furthermore, the two ends of the compression spring 20 abut against the inner wall of the compression roller mounting frame 16 and the roller frame 18 respectively, and the bonding pressure is adjusted by the pre-tightening force to avoid deformation of the copper wire cross section and damage to the paint film.

[0033] In use, firstly, the copper wire is drawn from the copper wire spool 4 and passed around the positioning roller 6, tension roller 7, and adjusting roller 8 in sequence. One end of the copper wire is temporarily fixed to a corner of the rectangular inner core by manual tape, completing the wiring preparation. Then, the winding parameters are preset by the touch screen controller 40 on the L-shaped support frame 39, the monitoring sensor 41 is activated, and the acquisition angle is calibrated to ensure that the winding status of the copper wire and the position of the rectangular inner core can be clearly captured. Next, the winding motor 3 and the unwinding motor 5 are started simultaneously. The reducer 2 drives the rectangular inner core to rotate at a constant speed, and the copper wire begins to be wound. When the rectangular inner core rotates to the corner position, the rotation radius increases, the follower slider 12 slides along the sliding hole of the fixed slider 13, the follower spring 14 is compressed and stored, pushing the follower slider 11 to slide upward along the vertical rod 10, and at the same time driving the vertical rod 10 to move away from the rectangular inner core along the horizontal rod 9. When rotated to the planar position, the radius of rotation decreases, the follower spring 14 resets, and pulls the follower slider 11 to move in the opposite direction, always conforming to the rectangular inner core trajectory to compensate for traction force fluctuations. Furthermore, as the follower slider 11 moves, the transmission vertical rod 21 drives the two transmission horizontal rods 22 to swing, driving the pressing roller mounting frame 16 to move synchronously along the adjusting slide bar 15 and the T-shaped mounting rod 23 along the adjusting slide bar 24, ensuring that the pressing roller 19 is always in contact with the wound copper wire. The pressing spring 20 adjusts the contact pressure through elastic extension and contraction, pressing the copper wire flat and preventing stacking. When the copper wire traction force is too high, the tension roller 7 moves along the T-shaped tensioning slide bar 25 towards the adjusting roller 8, squeezing the tension spring 27 to generate reverse tension and reduce the traction force. When the traction force is too small, the tension spring 27 resets, pushing the tension roller 7 to move in the opposite direction, increasing the tension and achieving adaptive adjustment. As the number of winding layers increases, the monitoring sensor 41 collects the signal of inner diameter expansion and feeds it back to the touch screen controller 40. The adjusting motor 29 starts automatically, driving the bevel gear 2 31 to rotate, which in turn drives the two adjusting screws 32 to rotate synchronously through the bevel gear 1 30. The adjusting screw (32) pushes the transmission horizontal rod (22) to move outward through the adjusting screw groove, driving the pressing roller (19) and the tension roller (7) to move outward synchronously, accurately matching the expansion of the inner diameter of the coil outer circumference, reducing the problem of increased force caused by the expansion of the inner diameter in the traditional static spring tensioning mechanism, thereby alleviating the phenomenon of increased tension fluctuation and reducing the tensile deformation of the copper wire due to increased tension. Simultaneously, the wiring motor 38 drives the bevel gears 37 and 36 to rotate, causing the wiring screw 33 to rotate. The wiring slider 35 moves horizontally along the wiring guide rod 34, pulling the copper wires to be evenly distributed along the inner core of the rectangle, ensuring consistent wiring spacing. Finally, when the number of winding layers reaches the preset value, the touch screen controller 40 controls the winding motor 3, unwinding motor 5, adjusting motor 29, and wiring motor 38 to gradually stop. The copper wires are manually cut, and the ends are fixed to the inner core of the rectangle, completing the winding of the trip coil. The touch screen controller 40 automatically stores the winding data, including winding time, speed parameters, and tension fluctuation range, for easy subsequent traceability. The monitoring sensor 41 performs visual inspection on the completed coil, providing feedback on issues such as copper wire stacking and enamel film damage.

[0034] The working principle of the rapid winding machine for circuit breaker trip coil provided by the present invention is as follows: As shown in Figures 1-5, firstly, the winding parameters are preset by the touch screen controller 40 of the electrical control monitoring mechanism, including the number of copper wire winding layers, wiring spacing, tension threshold, etc., and the monitoring sensor 41 is calibrated at the initial position. The rectangular inner core to be wound is fixed at the output shaft end of the reducer 2. The copper wire on the copper wire drum 4 passes through the positioning roller 6, tension roller 7, and adjusting roller 8 in sequence, and is finally fixed to the surface of the rectangular inner core, completing the wiring preparation before winding. After the winding is started, the winding motor 3 drives the reducer 2 to run, driving the rectangular inner core to rotate at a uniform speed. At the same time, the unwinding motor 5 synchronously drives the copper wire drum 4 to unwind. The copper wire is gradually wound under the rotational traction force of the rectangular inner core. During this process, the difference in rotation radius between the inner corner of the rectangle and the plane will cause fluctuations in the traction force of the copper wire, as shown in Figures 4 and 6. The follow-up linkage adjustment mechanism starts to compensate synchronously: the fixed slider 13 rotates synchronously with the shaft end of the reducer 2, and the follower slider 12 slides with the fixed slider 13 through the sliding hole. When the rotation radius changes, the follower spring 14 generates a force through elastic extension and contraction, driving the follower slider 11 to slide up and down along the vertical rod 10, and at the same time driving the vertical rod 10 to slide horizontally along a pair of horizontal rods 9, so that the movement trajectory of the follower slider 11 is... It fits against the outer periphery of the rectangular inner core to achieve basic traction force fluctuation compensation; as shown in Figures 2 and 3, and Figures 5-7, when the follower slider 11 moves, it drives the pressing and leveling mechanism and the tensioning roller 7 to adjust synchronously through the transmission rod group: the transmission rod 21 of the transmission rod group moves with the follower slider 11, driving the two transmission horizontal rods 22 to swing synchronously, thereby driving the pressing roller mounting frame 16 to slide along the adjusting slide rod 15 and the T-shaped mounting rod 23 along the adjusting slide rod 24, so that the pressing roller 19 and the tensioning roller 7 always maintain a suitable distance from the rectangular inner core. The tension roller 7 is linked to the connecting block 26 via the T-shaped tensioning slide 25. When the traction force fluctuates, the tension roller 7 moves along the T-shaped tensioning slide 25 to compress the tension spring 27. The spring stores force to generate reverse tension, realizing adaptive adjustment of copper wire tension and avoiding copper wire slack or overstretching. At the same time, the pressing and leveling mechanism works simultaneously: the two ends of the pressing spring 20 abut against the inner wall of the pressing roller mounting frame 16 and the roller frame 18. Through the pre-tightening force, the pressing roller 19 is pushed to flexibly fit with the copper wire being wound. With the rotation of the pressing roller 19, the copper wire is flatly pressed onto the outer periphery of the rectangular inner core, avoiding copper wire misalignment and stacking, and improving the flatness of the winding. Furthermore, the elastic buffering effect of the compression spring 20 can prevent excessive pressure from causing deformation of the copper wire cross section and damage to the paint film. As the number of copper wire winding layers increases, the inner diameter of the rectangular inner core gradually expands, and the multi-layer inner diameter compensation mechanism starts electronic fine adjustment: the touch screen controller 40 controls the operation of the adjustment motor 29 according to the winding layer data collected by the monitoring sensor 41, as shown in Figure 8, which drives the second bevel gear 31 to rotate. Through the meshing transmission with the first bevel gear 30, it drives the two adjustment screws 32 to rotate synchronously.The adjusting screw 32 engages with the transmission rod 22 via an adjusting screw groove, pushing the transmission rod 22 to move the pressing roller mounting frame 16 and the T-shaped mounting rod 23 outward along the adjusting slide rod 15 and adjusting slide rod 24. This is used to match the expansion of the coil inner diameter, replacing the passive force compensation method of the traditional static spring tensioning mechanism. This reduces the aggravated tension fluctuation caused by the increased spring force, thereby ensuring uniform force on the copper wire during multi-layer winding and reducing the risk of copper wire stretching deformation. The wiring mechanism simultaneously achieves uniform axial arrangement of the copper wire: as shown in Figure 5, the wiring motor 38 drives the bevel gear 4 37 to rotate, which in turn drives the wiring screw through meshing with the bevel gear 36. 33 operates, and the wiring slider 35 slides horizontally along the wiring guide rod 34, driving the adjusting roller 8 to move synchronously, thereby pulling the copper wire to be uniformly distributed along the inner core of the rectangle, avoiding local dense and sparse copper wires; throughout the entire winding process, the electrical control monitoring mechanism provides full control: as shown in Figure 4, the monitoring sensor 41 collects data such as the number of copper wire winding layers, tension status, and winding flatness in real time, and feeds it back to the touch screen controller 40. The touch screen controller 40 dynamically adjusts the operating speed of the winding motor 3, the unwinding motor 5, the adjusting motor 29, and the wiring motor 38 according to preset parameters, realizing the coordinated linkage of various components, while recording winding data to ensure the stable winding quality of the trip coil.

[0035] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention.

Claims

1. A rapid winding machine for circuit breaker tripping coils, characterized in that: The system includes a rectangular frame (1), a reducer (2), a winding motor (3), a copper wire drum (4), an unwinding motor (5), a positioning roller (6), a tension roller (7), an adjusting roller (8), a wiring mechanism, and an electrical control monitoring mechanism. The winding motor (3) drives the reducer (2). The rectangular inner core to be wound is fixed to the output shaft end of the reducer (2) and wound with it. The unwinding motor (5) drives the copper wire drum (4) to unwind the copper wire. The copper wire passes through the positioning roller (6), the tension roller (7), and the adjusting roller (8) in sequence and is then fixed to the rectangular inner core. The system also includes a follow-up linkage adjustment mechanism, a pressing and leveling mechanism, and a multi-layer inner diameter compensation mechanism. The three work together to eliminate the difference in the rotation radius between the corners of the rectangular inner core and the plane, and the fluctuation of the copper wire traction force caused by the change of the inner diameter of the multi-layer winding. The system also includes a transmission rod group. The follow-up linkage adjustment mechanism is connected to the pressing and leveling mechanism and the tension roller (7) through the transmission rod group. The multi-layer inner diameter compensation mechanism is assembled at the bottom of the transmission rod group to adapt to the change of inner diameter and avoid the stretching and deformation of the copper wire.

2. The rapid winding machine for a circuit breaker tripping coil according to claim 1, characterized in that: The follow-up linkage adjustment mechanism includes a pair of horizontal bars (9), a vertical bar (10), a follow-up slider (11), a follow-up slide rod (12), a fixed slider (13), and a follow-up spring (14). The vertical bar (10) is slidably assembled between the two horizontal bars (9). The follow-up slider (11) is slidably sleeved on the vertical bar (10). One end of the follow-up slide rod (12) is fixedly connected to the follow-up slider (11). The fixed slider (13) is fixedly connected to the shaft end of the reducer (2) and slides in cooperation with the end of the follow-up slide rod (12) away from the follow-up slider (11). The follow-up spring (14) is sleeved on the outer periphery of the follow-up slide rod (12), and its two ends abut against the fixed slider (13) and the follow-up slider (11) respectively.

3. A rapid winding machine for a circuit breaker tripping coil according to claim 1, characterized in that: The pressing and leveling mechanism includes a pair of adjusting slide rods (15), a pressing roller mounting frame (16), a T-shaped pressing slide rod (17), a roller frame (18), a pressing roller (19), and a pressing spring (20). The two adjusting slide rods (15) are symmetrically slidably connected inside the rectangular frame (1). The pressing roller mounting frame (16) is fixedly connected to one end of the four adjusting slide rods (15) facing the inner core of the rectangle. The T-shaped pressing slide rod (17) symmetrically slides through the pressing roller mounting frame (16). The roller frame (18) is fixedly connected to the ends of the two T-shaped pressing slide rods (17). The pressing roller (19) is rotatably connected inside the roller frame (18). The pressing spring (20) is sleeved on the outer periphery of the T-shaped pressing slide rod (17) and drives the pressing roller (19) to flexibly adhere to the copper wire.

4. A rapid winding machine for a circuit breaker tripping coil according to claim 1, characterized in that: The transmission rod assembly consists of a transmission vertical rod (21) and two transmission horizontal rods (22). The two transmission horizontal rods (22) are respectively hinged to the T-shaped mounting rods (23) corresponding to the pressing roller mounting frame (16) and the tensioning roller (7). A pair of adjusting slide rods (24) are symmetrically fixed to the T-shaped mounting rods (23). The adjusting slide rods (24) slide with the rectangular frame (1). When the follower slider (11) moves along the rotation trajectory of the rectangular inner core, the transmission rod assembly synchronously drives the tensioning roller (7) and the pressing roller (19) to adjust the distance with the rectangular inner core.

5. A rapid winding machine for a circuit breaker tripping coil according to claim 1, characterized in that: The installation structure of the tension roller (7) includes a T-shaped tension slide bar (25), a connecting block (26), and a tension spring (27). The T-shaped tension slide bar (25) is slidably connected to the T-shaped mounting rod (23), the tension roller (7) is rotatably connected to the connecting block (26), the connecting block (26) is fixedly connected to the T-shaped tension slide bar (25), and the tension spring (27) is sleeved on the outer periphery of the T-shaped tension slide bar (25). When the tension roller (7) moves along the T-shaped tension slide bar (25) close to the adjusting roller (8), it squeezes the tension spring (27) to store force, thereby realizing adaptive adjustment of copper wire tension.

6. A rapid winding machine for a circuit breaker tripping coil according to claim 1, characterized in that: The multi-layer inner diameter compensation mechanism includes an adjustment frame (28), an adjustment motor (29), a bevel gear one (30), a bevel gear two (31), and two adjustment screws (32). The adjustment frame (28) is fixed to the bottom of the transmission rod (21). The adjustment motor (29) is fixed to the outside of the adjustment frame (28), and its output end is fixed to the bevel gear two (31). The two adjustment screws (32) are symmetrically rotated and assembled inside the adjustment frame (28). One end extends to the outside and has an adjustment screw groove. The other end is fixed to the bevel gear one (30). The bevel gear one (30) meshes with the bevel gear two (31). The adjustment screw groove is threaded with the corresponding transmission rod (22).

7. A rapid winding machine for a circuit breaker tripping coil according to claim 1, characterized in that: The wiring mechanism includes a wiring screw (33), a wiring guide rod (34), a wiring slider (35), a bevel gear three (36), a bevel gear four (37), and a wiring motor (38) disposed inside a rectangular frame (1). The wiring slider (35) is slidably sleeved on the wiring guide rod (34). An adjusting roller (8) is rotatably connected to one end of the wiring slider (35). The wiring slider (35) is threadedly engaged with the wiring screw (33). The bevel gear three (36) is fixedly connected to the shaft end of the wiring screw (33). The bevel gear four (37) meshes with the bevel gear three (36) and is fixedly connected to the output end of the wiring motor (38).

8. A rapid winding machine for a circuit breaker tripping coil according to claim 1, characterized in that: The electrical control monitoring mechanism includes an L-shaped support frame (39) fixed on the top of the rectangular frame (1). The L-shaped support frame (39) is equipped with a touch screen controller (40) and a monitoring sensor (41). The touch screen controller (40) is electrically connected to the winding motor (3), the unwinding motor (5), the adjusting motor (29), and the wiring motor (38) to realize the coordinated control of each component and the recording of winding data.

9. A rapid winding machine for a circuit breaker tripping coil according to claim 2, characterized in that: The fixed slider (13) has a sliding hole. The end of the follower slider (12) away from the follower slider (11) passes through the sliding hole and slides. The follower spring (14) compensates for the difference in rotation radius through elastic extension and drives the follower slider (11) to slide in both directions along the vertical rod (10) and the horizontal rod (9).

10. A rapid winding machine for a circuit breaker tripping coil according to claim 3, characterized in that: The two ends of the compression spring (20) abut against the inner wall of the compression roller mounting frame (16) and the roller frame (18) respectively. The bonding pressure is adjusted by the pre-tightening force to avoid deformation of the copper wire cross section and damage to the paint film.

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