Copper wire guiding device for transformer coil production
By adopting a mechanical design for a copper wire guiding device in transformer coil production, the problems of equipment damage and high failure rate caused by copper wire breakage have been solved, enabling rapid braking and clean conveying, and improving equipment stability and cleanliness.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- ANHUI TIGER CO LTD
- Filing Date
- 2026-04-06
- Publication Date
- 2026-05-19
AI Technical Summary
In existing technologies, copper wires are prone to breakage during the production of transformer coils due to mechanical vibration and equipment debris. The broken copper wires can then entangle equipment parts, causing equipment damage. Furthermore, traditional electrical control systems have a high failure rate in braking.
Design a copper wire guiding device that uses a ceramic guide wheel and a V-shaped structure, combined with a mechanical position calibration component and a protective component, including a collar, pull rope, pawl and protective component, to achieve rapid braking and position correction when the copper wire breaks, use ball bearings to straighten the copper wire, and use a brush and air vent to clean impurities.
It effectively avoids damage to equipment after copper wire breakage, reduces the failure rate, improves the stability and cleanliness of copper wire conveying, reduces the difficulty of cleaning wear and adhering substances, and completes the braking response time within 0.3 seconds.
Smart Images
Figure CN122067918A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of coil manufacturing technology, and in particular to a copper wire guiding device for transformer coil production. Background Technology
[0002] The transformer coil is the core component of a transformer, responsible for electromagnetic induction and energy transfer. When alternating current passes through one coil (primary coil), it generates an alternating magnetic field. This alternating magnetic field passes through another coil (secondary coil), and according to Faraday's law of electromagnetic induction, an alternating electromotive force (voltage) is induced in the secondary coil. By changing the turns ratio of the two coils, the voltage can be increased or decreased.
[0003] There is a patent application with publication number CN105390263B entitled "A Wire Storage and Feeding Device for Transformer Production and Processing," which includes a wire feeding device and a wire storage device. The wire feeding device includes a wire feeding frame, multiple infeed rollers, multiple outfeed rollers, a wire threading plate, multiple wire threading heads, and an adjusting plate. The wire storage device includes a wire storage frame, multiple insertion posts, and multiple lead boxes. The beneficial effects of this invention are that the wire threading heads serve as a receiving element; the screws and pressure heads on the adjusting plate can adjust the copper wire tension during the wire feeding stage; and the position of the adjusting plate and the depth of the screws can be adjusted according to actual conditions. The soft layer mainly serves to protect the copper wire during tension adjustment. The pressure plates on the insertion posts stabilize the rollers winding the copper wire. The knobs and lead rods in the lead boxes are used to adjust the initial feeding path of the copper wire, which is closely related to subsequent adjustments and has a reserve function. The large and small lead rollers in the lead boxes are copper wire feeding tools, assisting in adjusting the path and feeding.
[0004] In the aforementioned prior art, the path is adjusted during the copper wire conveying process. During the copper wire winding process, mechanical vibration and debris generated during equipment operation can cause the copper wire to break during conveying. After the copper wire breaks, the guide wheel continues to rotate, and the broken copper wire will become entangled under the action of the guide wheel, and the copper wire will also hit the equipment parts, which will have an impact on the equipment. Summary of the Invention
[0005] The purpose of this invention is to address the shortcomings of existing technologies by providing a copper wire guiding device for transformer coil production.
[0006] To achieve the above objectives, the present invention adopts the following technical solution: Design a copper wire guiding device for transformer coil production, comprising two frames, with an air inlet box arranged laterally between the two frames: A bearing is fixed between the two frames, and a rotating shaft is rotatably arranged between the two bearings. A guide wheel is fixedly installed at the middle position of the rotating shaft, and a groove is provided at the middle position of the guide wheel. When feeding the wire, the copper wire is located inside the groove. A position calibration assembly is provided between the two racks for calibrating the position of the copper wires.
[0007] Preferably, the position calibration component includes a first pull rope, a collar, and a second pull rope; The collar is sleeved on the outside of the copper wire. The first pull rope and the second pull rope are symmetrically connected to the collar. The other ends of the first pull rope and the second pull rope are fixed. The deflection angle and length of the first pull rope and the second pull rope are set to be the same.
[0008] Preferably, the other end of the first pull rope is fixedly connected to a swing arm, the other end of the second pull rope is fixed to one of the frames, a support plate is horizontally installed at the bottom of the other frame, a return spring is connected between the support plate and the swing arm, a fixed seat is fixed on one side of the frame, and the bottom of the swing arm is hinged to the inside of the fixed seat.
[0009] Preferably, a pawl is installed on the top of the swing arm, and a ratchet is fixedly installed on the outer side of the rotating shaft, with the ratchet and the pawl cooperating with each other.
[0010] Preferably, the guide wheel is made of ceramic and is V-shaped.
[0011] Preferably, the inner side of the collar is provided with a plurality of spherical grooves, and a ball is rotatably disposed inside the spherical groove, and the size of the ball matches the inner size of the spherical groove.
[0012] Preferably, one side of the ball extends to the outside of the spherical groove, and the diameter of the ball is larger than the diameter at the port of the spherical groove. When the copper wire passes through the collar, the copper wire and the outer surface of the ball come into contact with each other.
[0013] Preferably, the lower end of the air intake box is symmetrically provided with connecting pipes, and a protective component is rotatably provided between the two connecting pipes, with the protective component located above the groove.
[0014] Preferably, the protective component includes a brush, an air vent, and a cylinder; The cylinder is positioned between two connecting pipes, and the interior of the cylinder is connected to the air inlet box via the connecting pipes. The brushes are evenly and fixedly installed on the outside of the cylinder, and the air sweeping port is opened through the outside of the cylinder.
[0015] Preferably, when the copper wire moves, its outer surface is in contact with the bottom of the brush.
[0016] The copper wire guiding device for transformer coil production proposed in this invention has the following advantages: When the copper wire breaks during the winding and conveying process of the transformer coil during production, the device can immediately stop and brake the guide wheel. At the same time, it can also correct the position of the copper wire during this process, thus avoiding the threat of damage to equipment parts and structure caused by the broken copper wire. Attached Figure Description
[0017] Figure 1 This is a schematic diagram of the structure of a copper wire guiding device for transformer coil production proposed in this invention.
[0018] Figure 2 This is a schematic diagram of the structure of a copper wire guiding device for transformer coil production proposed in this invention from another perspective.
[0019] Figure 3 This is a schematic diagram of the ratchet and pawl structure of a copper wire guiding device for transformer coil production proposed in this invention.
[0020] Figure 4 This is a schematic diagram of the protective component of a copper wire guiding device for transformer coil production proposed in this invention.
[0021] Figure 5 This is a schematic diagram of the collar structure of a copper wire guiding device for transformer coil production proposed in this invention.
[0022] Figure 6 for Figure 5 A side view of the structure of a copper wire guiding device for transformer coil production is presented.
[0023] In the diagram: 1. Inlet box; 2. Connecting pipe; 3. Protective component; 31. Brush; 32. Sweeping port; 33. Cylinder; 4. Frame; 5. Ratchet; 6. Pawl; 7. Swing arm; 8. Return spring; 9. Fixing seat; 10. First pull rope; 11. Collar; 12. Copper wire; 13. Second pull rope; 14. Shaft seat; 15. Rotating shaft; 16. Support plate; 17. Guide wheel; 18. Groove; 19. Spherical groove; 20. Ball bearing. Detailed Implementation
[0024] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.
[0025] Example 1, referring to Figure 1-3A copper wire guiding device for transformer coil production includes two frames 4, an air inlet box 1 is arranged between the two frames 4 laterally, a bearing 14 is fixed between the two frames 4, a rotating shaft 15 is rotatably arranged between the two bearings 14, a guide wheel 17 is fixedly installed in the middle of the rotating shaft 15, the guide wheel 17 is made of ceramic and is V-shaped, and a groove 18 is provided in the middle of the guide wheel 17. When feeding the wire, the copper wire 12 is located inside the groove 18. A position calibration assembly is provided between the two racks 4 for calibrating the position of the copper wire 12. The position calibration assembly includes a first pull rope 10, a collar 11, and a second pull rope 13. The collar 11 is sleeved on the outside of the copper wire 12. The first pull rope 10 and the second pull rope 13 are symmetrically connected to the collar 11. The other ends of the first pull rope 10 and the second pull rope 13 are fixed, and the deflection angle and length of the first pull rope 10 and the second pull rope 13 are set to be the same.
[0026] The other end of the first pull rope 10 is fixedly connected to the swing arm 7, and the other end of the second pull rope 13 is fixed to one of the frames 4. A support plate 16 is horizontally installed at the bottom of the other frame 4. A return spring 8 is connected between the support plate 16 and the swing arm 7. A fixed seat 9 is fixed on one side of the frame 4, and the bottom of the swing arm 7 is hinged to the inside of the fixed seat 9. A pawl 6 is installed on the top of the swing arm 7, and a ratchet 5 is fixedly installed on the outside of the rotating shaft 15. The ratchet 5 and the pawl 6 cooperate with each other.
[0027] During the production of transformer coils, copper wire 12 needs to be wound onto the coil. The copper wire 12 is fed out from the wire feeding device, and one end of the copper wire 12 is fixed to the winding equipment. The position and direction of the two are adjusted by using guide wheel 17.
[0028] Between the two frames 4, the rotation of the shaft 15 causes the guide wheel 17 to rotate. When the copper wire 12 is located in the groove 18 on the outside of the guide wheel 17, the guide wheel 17 is rotated during the feeding process of the copper wire 12. At the same time, the guide wheel 17 is made of hollow ceramic material, which can effectively suppress the generation of static electricity and the accumulation of dust. The guide wheel 17 is V-shaped, which can stably confine the copper wire 12 to move in the groove 12 in the middle position.
[0029] When the copper wire 12 breaks, the guide wheel 17 will continue to rotate, causing the copper wire 12 to wrap around the outside of the guide wheel 17. During the swinging of the guide wheel 17, the copper wire 12 will hit the equipment, causing damage to the equipment's parts.
[0030] Therefore, a collar 11 is fitted around the outside of the copper wire 12. The collar 11 can be an integral part or a combination thereof, and is fixed by a buckle. Before feeding the copper wire 12, the collar 11 is fixed on the side where the copper wire 12 is about to enter the guide wheel 17. The collar 11 is fixed between the two frames 4 by the first pull rope 10 and the second pull rope 13, keeping the collar 11 and the copper wire 12 in the same vertical plane. The first pull rope 10 and the second pull rope 13 are inclined downwards. The bottom of the first pull rope 10 is fixed to the lower end of the swing arm 7, and the swing arm 7 is fixed by the return spring 8. During the wire feeding process, the copper wire 12 will have tension, causing the first pull rope 10 to pull the swing arm 7 upwards. At this time, the return spring 8 is in the extended state. This design maintains the copper wire 12 at a suitable tension. When the copper wire 12 breaks during transport, the collar 11 on the copper wire 12 will fall off naturally, causing the first pull rope 10 and the second pull rope 13 to deflect. The swing arm 7 connected to the lower end of the first pull rope 10 swings downward under the action of the return spring 8. At this time, the pawl 6 at the upper end of the swing arm 7 engages with the ratchet 5 on the outside of the rotating shaft 15, achieving braking. This design can effectively control the position of the copper wire 12 during transport, preventing the copper wire 12 from being in a relaxed tension state. It can also prevent the copper wire 12 from breaking after a breakage, replacing the malfunctions of traditional electric control systems for braking. The mechanical design reduces the failure rate, and the braking response is within 0.3 seconds.
[0031] Example 2, Reference Figure 5-6 The difference between this embodiment and embodiment 1 is that a plurality of spherical grooves 19 are evenly provided on the inner side of the collar 11, and a ball bearing 20 is rotatably arranged on the inner side of the spherical groove 19. The size of the ball bearing 20 matches the inner size of the spherical groove 19. One side of the ball bearing 20 extends to the outer side of the spherical groove 19, and the diameter of the ball bearing 20 is larger than the diameter at the end of the spherical groove 19. When the copper wire 12 passes through the collar 11, the copper wire 12 and the outer surface of the ball bearing 20 come into contact with each other.
[0032] During the winding process of copper wire 12, deformation and bending problems often occur. Under the premise of high-speed transmission, it is necessary to straighten it.
[0033] Several spherical grooves 19 are evenly distributed on the inner side of the collar 11, and ball bearings 20 are provided on the inner side of the spherical grooves 19. When the copper wire 12 passes through the collar 11, it will come into contact with the ball bearings 20. During the contact process, the ball bearings 20 will rotate inside the spherical grooves 19. In this way, compared with the traditional straightening method of sliding friction, the copper wire 12 is straightened by using rolling friction to generate a smaller friction force, which can reduce the wear on the surface of the copper wire 12 and remove larger impurities that may adhere to the copper wire 12 before it enters the guide wheel 17.
[0034] Example 3, Reference Figure 4 The difference between this embodiment and Embodiment 1 and Embodiment 2 is that the lower end of the air intake box 1 is symmetrically provided with connecting pipes 2, and a protective component 3 is rotatably provided between the two connecting pipes 2. The protective component 3 is located above the groove 18. The protective component 3 includes a brush 31, an air sweeping port 32, and a cylinder 33. The cylinder 33 is positioned between two connecting pipes 2. The interior of the cylinder 33 is connected to the air inlet box 1 through the connecting pipes 2. The brushes 31 are evenly and fixedly installed on the outside of the cylinder 33. The air inlet 32 is opened through the outside of the cylinder 33. When the copper wire 12 moves, its outer surface is in contact with the bottom of the brush 31.
[0035] During the process of conveying copper wire 12 inside the groove 18, some debris and impurity particles often appear. When these impurity particles appear inside the groove 18, they will cause wear problems during the conveying of copper wire 12.
[0036] To this end, a brush is installed at the upper end of the copper wire 12 to clean the inside of the groove 18 by simultaneously sweeping air and scraping. An air pump delivers air to the air inlet box 1 and then to the cylinder 33 through the connecting pipe 2. As the copper wire 12 moves, it comes into contact with the brush 31 above, thereby cleaning the surface of the copper wire 12 and the inside of the groove 18. Air is blown out from the air inlet 32, which on the one hand cleans the debris and impurities in the groove 18, and on the other hand, because the copper wire 12 cannot be completely dried during transportation, some lubricating oil or other liquids will adhere to the groove 18. Ordinary cleaning cannot remove them. At this time, the air is blown dry by blowing air, and these liquids lose their ability to adhere to the debris, making it easier to remove them from the groove 18. At the same time, air is blown out from the air inlet 32 in multiple directions, forming multiple air barriers in the area where the copper wire 12 contacts the groove 18, so that except for the dust and debris originally adhering to the copper wire 12, other dust and debris cannot fall to the inside of the groove 18.
[0037] The working principle of this device is as follows: During the production of transformer coils, copper wire 12 needs to be wound onto the coil. The copper wire 12 is fed out from the wire feeding device, and one end of the copper wire 12 is fixed to the winding equipment. The position and direction of the two are adjusted by using guide wheel 17.
[0038] Between the two frames 4, the rotation of the shaft 15 causes the guide wheel 17 to rotate. When the copper wire 12 is located in the groove 18 on the outside of the guide wheel 17, the guide wheel 17 is rotated during the feeding process of the copper wire 12. At the same time, the guide wheel 17 is made of hollow ceramic material, which can effectively suppress the generation of static electricity and the accumulation of dust. The guide wheel 17 is V-shaped, which can stably confine the copper wire 12 to move in the groove 12 in the middle position.
[0039] When the copper wire 12 breaks, the guide wheel 17 will continue to rotate, causing the copper wire 12 to wrap around the outside of the guide wheel 17. During the swinging of the guide wheel 17, the copper wire 12 will hit the equipment, causing damage to the equipment's parts.
[0040] Therefore, a collar 11 is fitted around the outside of the copper wire 12. The collar 11 can be an integral part or a combination thereof, and is fixed by a buckle. Before feeding the copper wire 12, the collar 11 is fixed on the side where the copper wire 12 is about to enter the guide wheel 17. The collar 11 is fixed between the two frames 4 by the first pull rope 10 and the second pull rope 13, keeping the collar 11 and the copper wire 12 in the same vertical plane. The first pull rope 10 and the second pull rope 13 are inclined downwards. The bottom of the first pull rope 10 is fixed to the lower end of the swing arm 7, and the swing arm 7 is fixed by the return spring 8. During the wire feeding process, the copper wire 12 will have tension, causing the first pull rope 10 to pull the swing arm 7 upwards. At this time, the return spring 8 is in the extended state. This design maintains the copper wire 12 at a suitable tension. When the copper wire 12 breaks during transport, the collar 11 on the copper wire 12 will fall off naturally, causing the first pull rope 10 and the second pull rope 13 to deflect. The swing arm 7 connected to the lower end of the first pull rope 10 swings downward under the action of the return spring 8. At this time, the pawl 6 at the upper end of the swing arm 7 engages with the ratchet 5 on the outside of the rotating shaft 15, achieving braking. This design can effectively control the position of the copper wire 12 during transport, preventing the copper wire 12 from being in a relaxed tension state. It can also prevent the copper wire 12 from breaking after a breakage, replacing the malfunctions of traditional electric control systems for braking. The mechanical design reduces the failure rate, and the braking response is within 0.3 seconds.
[0041] During the winding process of copper wire 12, deformation and bending problems often occur. Under the premise of high-speed transmission, it is necessary to straighten it.
[0042] Several spherical grooves 19 are evenly distributed on the inner side of the collar 11, and ball bearings 20 are provided on the inner side of the spherical grooves 19. When the copper wire 12 passes through the collar 11, it will come into contact with the ball bearings 20. During the contact process, the ball bearings 20 will rotate inside the spherical grooves 19. In this way, compared with the traditional straightening method of sliding friction, the copper wire 12 is straightened by using rolling friction to generate a smaller friction force, which can reduce the wear on the surface of the copper wire 12 and remove larger impurities that may adhere to the copper wire 12 before it enters the guide wheel 17.
[0043] During the process of conveying copper wire 12 inside the groove 18, some debris and impurity particles often appear. When these impurity particles appear inside the groove 18, they will cause wear problems during the conveying of copper wire 12.
[0044] To this end, a brush is installed at the upper end of the copper wire 12 to clean the inside of the groove 18 by simultaneously sweeping air and scraping. An air pump delivers air to the air inlet box 1 and then to the cylinder 33 through the connecting pipe 2. As the copper wire 12 moves, it comes into contact with the brush 31 above, thereby cleaning the surface of the copper wire 12 and the inside of the groove 18. Air is blown out from the air inlet 32, which on the one hand cleans the debris and impurities in the groove 18, and on the other hand, because the copper wire 12 cannot be completely dried during transportation, some lubricating oil or other liquids will adhere to the groove 18. Ordinary cleaning cannot remove them. At this time, the air is blown dry by blowing air, and these liquids lose their ability to adhere to the debris, making it easier to remove them from the groove 18. At the same time, air is blown out from the air inlet 32 in multiple directions, forming multiple air barriers in the area where the copper wire 12 contacts the groove 18, so that except for the dust and debris originally adhering to the copper wire 12, other dust and debris cannot fall to the inside of the groove 18.
[0045] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.
Claims
1. A copper wire guiding device for transformer coil production, comprising two frames (4), wherein an air inlet box (1) is arranged laterally between the two frames (4), characterized in that: A bearing seat (14) is fixed between the two frames (4), and a rotating shaft (15) is rotatably arranged between the two bearing seats (14). A guide wheel (17) is fixedly installed in the middle of the rotating shaft (15), and a groove (18) is provided in the middle of the guide wheel (17). When feeding the wire, the copper wire (12) is located inside the groove (18). A position calibration assembly is provided between the two racks (4) for calibrating the position of the copper wire (12).
2. The copper wire guiding device for transformer coil production according to claim 1, characterized in that, The position calibration component includes a first pull rope (10), a collar (11), and a second pull rope (13). The collar (11) is sleeved on the outside of the copper wire (12). The first pull rope (10) and the second pull rope (13) are symmetrically connected on the collar (11). The other ends of the first pull rope (10) and the second pull rope (13) are fixed, and the deflection angle and length of the first pull rope (10) and the second pull rope (13) are set to be the same.
3. The copper wire guiding device for transformer coil production according to claim 2, characterized in that, The other end of the first pull rope (10) is fixedly connected to a swing arm (7), and the other end of the second pull rope (13) is fixed on one of the frames (4). A support plate (16) is horizontally installed at the bottom of the other frame (4). A return spring (8) is connected between the support plate (16) and the swing arm (7). A fixed seat (9) is fixed on one side of the frame (4), and the bottom of the swing arm (7) is hinged to the inside of the fixed seat (9).
4. The copper wire guiding device for transformer coil production according to claim 3, characterized in that, A pawl (6) is installed on the top of the swing arm (7), and a ratchet (5) is fixedly installed on the outside of the rotating shaft (15). The ratchet (5) and the pawl (6) cooperate with each other.
5. The copper wire guiding device for transformer coil production according to claim 1, characterized in that, The guide wheel (17) is made of ceramic and is V-shaped.
6. The copper wire guiding device for transformer coil production according to claim 1, characterized in that, The inner side of the collar (11) is provided with a plurality of spherical grooves (19), and a ball (20) is rotatably provided on the inner side of the spherical groove (19), and the size of the ball (20) matches the inner size of the spherical groove (19).
7. The copper wire guiding device for transformer coil production according to claim 6, characterized in that, One side of the ball (20) extends to the outside of the spherical groove (19), and the diameter of the ball (20) is larger than the diameter at the port of the spherical groove (19). When the copper wire (12) passes through the collar (11), the copper wire (12) and the outer surface of the ball (20) come into contact with each other.
8. The copper wire guiding device for transformer coil production according to claim 1, characterized in that, The lower end of the air intake box (1) is symmetrically provided with connecting pipes (2), and a protective component (3) is rotatably provided between the two connecting pipes (2), and the protective component (3) is located above the groove (18).
9. The copper wire guiding device for transformer coil production according to claim 8, characterized in that, The protective component (3) includes a brush (31), an air vent (32), and a cylinder (33); The cylinder (33) is located between two connecting pipes (2). The interior of the cylinder (33) is connected to the air inlet box (1) through the connecting pipes (2). The brush (31) is evenly fixed on the outside of the cylinder (33). The air inlet (32) is opened through the outside of the cylinder (33).
10. The copper wire guiding device for transformer coil production according to claim 9, characterized in that, When the copper wire (12) moves, its outer surface is in contact with the bottom of the brush (31).