A kind of fine enamel wire anti-breakage precision winding device
By combining the tension wheel with the arc block and adjusting the spring's buffer, the problem of enamel film damage caused by tension fluctuations during the winding of fine enameled wire was solved, thus improving the stability and yield of the winding.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- HUIZHOU CHUANGYIWEI ELECTRONIC TECH CO LTD
- Filing Date
- 2026-04-22
- Publication Date
- 2026-05-29
AI Technical Summary
Existing fine enameled wire winding devices are prone to problems such as enamel film damage, wire stretching damage, and wire breakage during the winding process. In particular, they cannot effectively adjust when the winding tension fluctuates, resulting in rigid deformation of the enamel film or insufficient tension leading to loose stacking and squeezing scratches on the wire.
The tensioning wheel and the arc-shaped block are intermittently contacted and engaged, and the spring is used for buffering adjustment to achieve adaptive adjustment of tension. The toothless area of the internal gear ring reduces inertial impact and avoids instantaneous peak tension damage.
It effectively prevents damage to the enamel film of fine enameled wire, improves the winding yield and stability, ensures that the enameled wire operates within the appropriate safe tension range, and reduces the risk of enamel film stretching and loosening.
Smart Images
Figure CN122117638A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of transformer winding device technology, and in particular to a fine enameled wire anti-damage precision winding device. Background Technology
[0002] Transformer fine enameled wire winding is a core process and the forming of the winding structure for achieving electromagnetic energy conversion and voltage transformation in transformers. Specifically, it refers to the precise winding of fine insulated enameled copper wire (aluminum wire in some applications) with a diameter of 0.02mm to 0.5mm onto the transformer core or insulating frame according to the number of turns, winding method, and arrangement rules required by the electrical design. It is the core unit constituting the primary and secondary windings of the transformer, achieving inter-turn and inter-layer electrical insulation through the insulating enamel film on the surface of the enameled wire, and transmitting the insulation through the metal conductor. It completes current transmission and achieves voltage rise / fall and electrical isolation functions by means of winding turns ratio. The fine wire diameter is suitable for the low loss and high space utilization requirements of high frequency, miniaturization and precision transformers. The winding process requires strict control of tension uniformity, wire flatness and turn accuracy to avoid paint film damage and wire diameter stretching deformation. At the same time, it is compatible with supporting processes such as interlayer insulation, lead wire welding and vacuum impregnation to ensure the winding insulation withstand voltage, temperature resistance and anti-aging performance. It is widely used in the manufacturing of small precision electromagnetic devices in the fields of consumer electronics, new energy and industrial control communication.
[0003] However, some existing precision winding devices for preventing damage to fine enameled wire still experience problems such as damage to the insulation film of the fine enameled wire, tensile damage to the wire substrate, and even wire breakage during actual transformer winding operations. The wire feeding mechanism of existing devices mostly adopts a single spring tensioner or a passive damping wire feeding structure, which cannot adapt to the tension fluctuations caused by the continuous decrease in wire diameter of the wire feeding reel during the winding process. This can easily lead to a sudden increase in tension, resulting in excessive stretching of the wire and rigid deformation and cracking of the enamel film, or insufficient tension, resulting in loose stacking of the wire, misalignment, squeezing, and scratching. During high-speed winding and winding at the winding end reversal, problems such as wire stacking, slot crossing, and wire skipping are very likely to occur, causing irreversible enamel film damage to the wire due to interlayer squeezing and scraping of the frame edges.
[0004] Therefore, a precision winding device for preventing damage to fine enameled wire is proposed to address the above problems. Summary of the Invention
[0005] To overcome the above deficiencies, the present invention provides a precision winding device for preventing damage to fine enameled wire.
[0006] To achieve the above objectives, the present invention adopts the following technical solution: A precision winding device for preventing damage to fine enameled wire includes a winding frame for winding transformer wire. A drive assembly is arranged on the left side of the winding frame. A gear is rotatably connected to the outside of the drive assembly. An internal gear ring is fixedly connected to the inside of the winding frame. A slider is fixedly connected to one side of the drive assembly. A sliding frame is slidably connected to the outside of the slider. A groove is opened inside the sliding frame. A sliding block is fixedly connected to one side of the sliding frame. A wire feeding assembly is arranged on one side of the sliding block. A connecting frame is fixedly connected to the bottom of the wire feeding assembly. A tensioning wheel is fixedly connected to one side of the connecting frame. A fixing rod is fixedly connected inside the winding frame. An arc-shaped block is fixedly connected to the outside of the fixing rod. An elastic component is arranged inside the tensioning wheel. A winding assembly is arranged outside the winding frame. As a further description of the above technical solution: The drive assembly includes a drive motor, one side of which is mounted on the outside of the winding frame. A rotating rod is fixedly connected to the output end of the drive motor, and a fixed shaft is rotatably connected inside the rotating rod. As a further description of the above technical solution: The wire feeding assembly includes a fixed frame, the outside of which is fixedly connected to the inside of the winding frame, and a mounting frame is fixedly connected to one side of the sliding block, with a wire feeding roll fixedly connected inside the mounting frame. As a further description of the above technical solution: The elastic component includes a fixed plate, the outside of which is fixedly connected to the inside of a tensioning wheel. The inside of the tensioning wheel is provided with a sliding groove. A sliding rod is slidably connected inside the fixed plate. A spring is sleeved on the outside of the sliding rod. An arc-shaped plate is fixedly connected to the top of the sliding rod. As a further description of the above technical solution: The winding assembly includes a take-up motor, one side of which is mounted on the outside of the winding frame. The output end of the take-up motor is fixedly connected to a drive shaft, and a clamping module is provided on the outside of the drive shaft. As a further description of the above technical solution: The gear and the internal gear ring are meshed together, and one side of the slider is fixedly connected to one side of the fixed shaft. As a further description of the above technical solution: The slider is externally slidably connected to the inside of the groove, and the sliding block is externally slidably connected to the inside of the fixed frame; As a further description of the above technical solution: One side of the mounting frame is slidably connected to the outside of the fixed frame, and one side of the connecting bracket is fixedly connected to the bottom of the wire reel; As a further description of the above technical solution: The inside of the tensioning wheel is in contact with the outside of the arc-shaped block, and the outside of the fixing rod is in contact with the outside of the arc-shaped plate; As a further description of the above technical solution: One end of the spring is fixedly connected to the bottom of the arc-shaped plate, and the other end of the spring is fixedly connected to the top of the fixed plate.
[0007] The present invention has the following beneficial effects: 1. In this invention, the tensioning wheel and the arc-shaped block make intermittent contact and cooperate. When the tensioning wheel moves with the unwinding coil, it contacts the arc-shaped block and triggers micro-displacement up and down. The spring extends and retracts to buffer the movement, thereby achieving adaptive adjustment of the micro-displacement of the tensioning wheel. This adapts to and adjusts the tension of the enameled wire, stabilizing the wire tension within a safe micro-tension range suitable for fine enameled wire. At the same time, the reversing buffer structure in the toothless areas on the left and right sides of the internal tooth ring further reduces the inertial impact of reciprocating winding, avoids the risk of breakage due to tension spikes at the moment of reversal, and achieves comprehensive protection against damage to the enamel film of fine enameled wire, significantly improving the yield and winding stability of transformer coil winding. Attached Figure Description
[0008] Figure 1 This is a three-dimensional schematic diagram of a precision winding device for preventing breakage of fine enameled wire proposed in this invention; Figure 2 This is a schematic diagram of the tensioning wheel structure of a precision winding device for preventing breakage of fine enameled wire proposed in this invention; Figure 3 This is a schematic diagram of the arc-shaped block structure of a precision winding device for preventing breakage of fine enameled wire proposed in this invention; Figure 4 This is a schematic diagram of the winding frame structure of a fine enameled wire anti-breakage precision winding device proposed in this invention; Figure 5 This is a schematic diagram of the mounting frame structure of a precision winding device for preventing breakage of fine enameled wire proposed in this invention; Figure 6 This is a schematic diagram of the sliding block structure of a precision winding device for preventing breakage of fine enameled wire proposed in this invention; Figure 7 This is a schematic diagram of the fixing rod structure of a precision winding device for preventing breakage of fine enameled wire proposed in this invention; Figure 8 for Figure 7 Enlarged view of point A in the middle.
[0009] Legend: 1. Winding frame; 2. Drive motor; 3. Rotating rod; 4. Fixed shaft; 5. Gear; 6. Internal gear ring; 7. Slider; 8. Sliding frame; 9. Slide groove; 10. Sliding block; 11. Fixed frame; 12. Mounting frame; 13. Unwinding coil; 14. Connecting frame; 15. Tensioning wheel; 16. Fixed rod; 17. Arc block; 18. Fixed plate; 19. Sliding groove; 20. Slide rod; 21. Spring; 22. Arc plate; 23. Rewinding motor; 24. Drive shaft; 25. Clamping module. Detailed Implementation
[0010] 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.
[0011] Reference Figures 1 to 3This invention provides an embodiment of a precision winding device for preventing damage to fine enameled wire, comprising a winding frame 1 for transformer winding. The winding frame 1 is the supporting base of the entire device, integrally cast from high-strength cast iron or aerospace aluminum alloy, and has a semi-enclosed rectangular frame structure. A drive assembly is provided on the left side of the winding frame 1, including a drive motor 2. One side of the drive motor 2 is mounted on the outside of the winding frame 1. The drive motor 2 is the power source for the reciprocating motion of the wire, and is a high-precision, low-inertia servo motor. The motor body is fastened to the left outer wall of the winding frame 1 by internal hexagonal bolts. A rotating rod 3 is fixedly connected to the output end of the drive motor 2. The rotating rod 3 is a power transmission adapter. When the drive motor 2 drives the rotating rod 3 to rotate, the gear 5 at the end of the fixed shaft 4 can always maintain the optimal meshing clearance with the internal gear ring 6. Its function is to transmit the rotational power of the drive motor 2 to the fixed shaft 4 and the gear 5 without deviation, driving the gear 5 to rotate along the internal gear ring 6. The gear ring 6 revolves in a circular motion. The rotating rod 3 is internally connected to a fixed shaft 4. The function of the fixed shaft 4 is to receive the revolution power of the rotating rod 3, drive the gear 5 to revolve in a circular motion, and at the same time realize the rotation of the gear 5 through its own rotational connection, adapting to the meshing transmission with the internal gear ring 6. The drive component is externally connected to the gear 5, and the winding frame 1 is internally fixedly connected to the internal gear ring 6. The left and right sides of the internal gear ring 6 have no teeth, which can reduce the problem of excessive inertia when the unwinding coil 13 starts, stops, and reverses during the reciprocating motion. The gear 5 and the internal gear ring 6 are meshed. The function of the gear 5 is to convert the circular revolution motion driven by the rotating rod 3 into the meshing rolling motion along the tooth surface of the internal gear ring 6 through the meshing transmission with the internal gear ring 6. At the same time, through the trajectory constraint of the meshing transmission, the fixed shaft 4 and the slider 7 are driven to move back and forth in the horizontal direction, providing the core trajectory drive for the reciprocating motion of the wire winding. Reference Figures 3 to 5A slider 7 is fixedly connected to one side of the drive component, and another side of the slider 7 is fixedly connected to one side of the fixed shaft 4. The function of the slider 7 is to receive the circular motion transmitted by the fixed shaft 4. While sliding back and forth in the groove 9, it drives the sliding frame 8 to perform a horizontal linear reciprocating motion, thereby converting the circular meshing motion of the gear 5 into the horizontal linear reciprocating motion of the sliding frame 8. It is the actuator that realizes the conversion of rotational motion into linear motion. The slider 7 is slidably connected to the outside of the sliding frame 8, and the sliding frame 8 has a groove 9 inside. The slider 7 is slidably connected to the inside of the groove 9. The function of the groove 9 is to constrain the motion trajectory of the slider 7, decomposing the circular motion of the slider 7 into the up and down sliding within the groove and the synchronous driving in the horizontal direction, thereby realizing the conversion of rotational motion into linear reciprocating motion. A sliding block 10 is fixedly connected to one side of the sliding frame 8. The function of the sliding block 10 is to hold the sliding frame 8... The horizontal linear reciprocating motion is synchronously and without deviation transmitted to the mounting frame 12, causing the mounting frame 12 to perform synchronous horizontal reciprocating motion along the fixed frame 11. A wire feeding assembly is provided on one side of the sliding block 10. The wire feeding assembly includes the fixed frame 11. The outside of the fixed frame 11 is fixedly connected to the inside of the winding frame 1, and the outside of the sliding block 10 is slidably connected to the inside of the fixed frame 11. The function of the fixed frame 11 is to provide precise linear guidance for the reciprocating motion of the sliding block 10 and the mounting frame 12. The mounting frame 12 is fixedly connected to one side of the sliding block 10, and one side of the mounting frame 12 is slidably connected to the outside of the fixed frame 11. The function of the mounting frame 12 is to provide a stable and detachable mounting carrier for the wire feeding coil 13, and at the same time bear the reciprocating driving force transmitted by the sliding block 10, causing the wire feeding coil 13 to perform precise horizontal linear reciprocating motion along the slide rail of the fixed frame 11, thereby realizing the axial wire feeding action during the transformer coil winding process. Reference Figures 4 to 6The mounting frame 12 has a wire unwinding reel 13 fixedly connected inside. The function of the wire unwinding reel 13 is to store the fine enameled wire to be wound. Under the traction of the winding motor 23, it moves back and forth axially with the mounting frame 12, synchronously completing the wire unwinding and winding actions, evenly releasing the enameled wire and conveying it to the tension wheel 15 mechanism. The bottom of the wire unwinding assembly is fixedly connected to a connecting frame 14. One side of the connecting frame 14 is fixedly connected to the bottom of the wire unwinding reel 13, and one side of the connecting frame 14 is fixedly connected to a tension wheel 15. The function of the tension wheel 15 is to move back and forth synchronously with the wire unwinding reel 13. Through cooperation with the arc block 17 and the elastic component, it can achieve micro-displacement and micro-adjustment of its own vertical movement, thereby adaptively adjusting the tension of the enameled wire. The winding frame 1 has a fixing rod 16 fixedly connected inside. The function of the fixing rod 16 is to support the arc block 17. The elastic component provides a stable installation and support reference, while also providing guidance for the horizontal reciprocating motion of the tension wheel 15 and providing support reference for the vertical micro-displacement adjustment of the tension wheel 15. An arc-shaped block 17 is fixedly connected to the outside of the fixed rod 16. The inside of the tension wheel 15 is in contact with the outside of the arc-shaped block 17. The arc-shaped block 17 is a guide component that triggers the vertical micro-displacement adjustment of the tension wheel 15. Its function is to intermittently contact and cooperate with the inner wall of the tension wheel 15 during the horizontal reciprocating motion of the tension wheel 15 with the unwinding reel 13. Through the contour guidance of the arc-shaped protrusion, the tension wheel 15 is pushed to make vertical micro-displacement adjustment. At the same time, in conjunction with the adaptive extension and retraction of the elastic component, the tension of the enameled wire is pre-adjusted to offset the sudden tension change during the reciprocating motion reversal and start-stop, and to prevent the wire from cracking the enamel film due to a sudden increase in tension. Reference Figures 6 to 8The tension wheel 15 has an internal elastic component, which includes a fixing plate 18. The fixing plate 18 is externally fixedly connected to the inside of the tension wheel 15. The function of the fixing plate 18 is to provide precise sliding guidance for the slide rod 20, and at the same time provide stable installation support and limit reference for the spring 21, ensuring that the slide rod 20 always slides up and down in the vertical direction. The tension wheel 15 has a sliding groove 19 inside. The sliding groove 19 is an auxiliary structure that provides limit and guidance for the up and down sliding of the arc plate 22 and the slide rod 20. The slide rod 20 is slidably connected inside the fixing plate 18. The function of the slide rod 20 is to bear the contact pressure transmitted by the arc plate 22, drive the spring 21 to perform adaptive extension and contraction deformation, and simultaneously transmit the rebound force of the spring 21 to the arc plate 22, so as to realize the adaptive tension force. The slide bar 20 is fitted with a spring 21. One end of the spring 21 is fixedly connected to the bottom of the arc plate 22, and the other end of the spring 21 is fixedly connected to the top of the fixed plate 18. The spring 21 is the core elastic component for achieving tension buffering and adaptive adjustment. Its function is to absorb the impact caused by sudden changes in wire tension through its own adaptive expansion and contraction deformation, and maintain the tension of the enameled wire in a safe and stable range suitable for fine enameled wire throughout the process, so as to avoid the sudden increase of tension tearing the enamel film and the sudden drop of tension loosening and scraping. The top of the slide bar 20 is fixedly connected to the arc plate 22. The outside of the fixed rod 16 is in contact with the outside of the arc plate 22. The function of the arc plate 22 is to always fit with the outer surface of the fixed rod 16 while the tension wheel 15 moves horizontally back and forth, and to bear the supporting reaction force of the fixed rod 16. Reference Figures 1 to 3 The winding frame 1 is equipped with a winding assembly, which includes a take-up motor 23. One side of the take-up motor 23 is mounted on the outside of the winding frame 1. The function of the take-up motor 23 is to output stable and shock-free rotational power, which drives the transformer coil skeleton fixed by the clamping module 25 to rotate at a uniform speed through the drive shaft 24, providing continuous and stable traction force for winding the enameled wire. The output end of the take-up motor 23 is fixedly connected to the drive shaft 24. The clamping module 25 is provided on the outside of the drive shaft 24. The clamping module 25 is a clamping and fixing component for the transformer coil skeleton. The module is equipped with a quick locking mechanism, which can realize the quick clamping and disassembly of the coil skeleton without additional tools.
[0012] Working principle: During operation, the drive motor 2 provides power to rotate the rotating rod 3. The fixed shaft 4, which is rotatably connected to the rotating rod 3, synchronously drives the gear 5 to perform circular motion. The gear 5 meshes with the internal gear ring 6 fixed to the inner wall of the winding frame 1, causing the gear 5 to roll along the contour of the internal gear ring 6. At the same time, the fixed shaft 4 drives the slider 7 to reciprocate within the groove 9 of the sliding frame 8, thereby converting the rotational motion of the drive motor 2 into the horizontal linear reciprocating motion of the sliding frame 8. The sliding frame 8 drives the mounting frame 12 to perform synchronous horizontal reciprocating motion along the fixed frame 11 through the sliding block 10, causing the unwinding coil 13 inside the mounting frame 12 to perform synchronous reciprocating motion. The unwinding coil 13 synchronously drives the tensioning wheel 15 to perform horizontal reciprocating motion along with the unwinding coil 13 through the connecting frame 14 at the bottom. During the reciprocating motion, the tensioning wheel 15 intermittently contacts the arc-shaped block 17 on the fixed rod 16 inside the winding frame 1. Simultaneously, the arc-shaped plate 22 inside the tensioning wheel 15 fits against the outer wall of the fixing rod 16. The arc-shaped plate 22 drives the slide rod 20 to make adaptive up-and-down fine-tuning slides along the fixing plate 18 and the sliding groove 19. With the extension and retraction buffer of the spring 21 sleeved on the outside of the slide rod 20, the tensioning wheel 15 makes up-and-down reciprocating fine-tuning. In turn, the reciprocating fine-tuning of the tensioning wheel 15 adapts to the adjustment of the tension of the enameled wire, counteracts the tension change caused by the reciprocating motion of the wire, and avoids the enameled wire film from stretching and cracking or loosening and scratching damage due to sudden increase or decrease in tension. The winding motor 23 on the winding frame 1 drives the transformer coil skeleton fixed by the clamping module 25 to rotate circumferentially through the drive shaft 24, continuously pulling the fine enameled wire that has been tensioned by the tensioning wheel 15. With the axial reciprocating wire laying action of the wire unwinding roll 13, the enameled wire is evenly, flatly and precisely wound on the transformer coil skeleton.
[0013] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A precision winding device for preventing damage to fine enameled wire, comprising a winding frame (1) for transformer winding, characterized in that: A drive assembly is provided on the left side of the winding frame (1). A gear (5) is rotatably connected to the outside of the drive assembly. An internal gear ring (6) is fixedly connected inside the winding frame (1). A slider (7) is fixedly connected to one side of the drive assembly. A sliding frame (8) is slidably connected to the outside of the slider (7). A groove (9) is opened inside the sliding frame (8). A sliding block (10) is fixedly connected to one side of the sliding frame (8). A wire feeding assembly is provided on one side of the sliding block (10). A connecting frame (14) is fixedly connected to the bottom of the wire feeding assembly. A tensioning wheel (15) is fixedly connected to one side of the connecting frame (14). A fixing rod (16) is fixedly connected inside the winding frame (1). An arc block (17) is fixedly connected to the outside of the fixing rod (16). An elastic assembly is provided inside the tensioning wheel (15). A winding assembly is provided outside the winding frame (1).
2. The precision winding device for preventing breakage of fine enameled wire according to claim 1, characterized in that: The drive assembly includes a drive motor (2), one side of which is mounted on the outside of the winding frame (1). A rotating rod (3) is fixedly connected to the output end of the drive motor (2), and a fixed shaft (4) is rotatably connected inside the rotating rod (3).
3. The precision winding device for preventing breakage of fine enameled wire according to claim 1, characterized in that: The wire feeding assembly includes a fixed frame (11), the outside of which is fixedly connected to the inside of the winding frame (1), and a mounting frame (12) is fixedly connected to one side of the sliding block (10), and a wire feeding roll (13) is fixedly connected inside the mounting frame (12).
4. The precision winding device for preventing breakage of fine enameled wire according to claim 1, characterized in that: The elastic component includes a fixed plate (18), the outside of which is fixedly connected to the inside of a tensioning wheel (15). The inside of the tensioning wheel (15) is provided with a sliding groove (19). The inside of the fixed plate (18) is slidably connected to a sliding rod (20). A spring (21) is sleeved on the outside of the sliding rod (20). An arc-shaped plate (22) is fixedly connected to the top of the sliding rod (20).
5. A precision winding device for preventing breakage of fine enameled wire according to claim 1, characterized in that: The winding assembly includes a take-up motor (23), one side of which is mounted on the outside of the winding frame (1). The output end of the take-up motor (23) is fixedly connected to a drive shaft (24), and a clamping module (25) is provided on the outside of the drive shaft (24).
6. A precision winding device for preventing breakage of fine enameled wire according to claim 2, characterized in that: The gear (5) and the internal gear ring (6) are meshed together, and one side of the slider (7) is fixedly connected to one side of the fixed shaft (4).
7. A precision winding device for preventing breakage of fine enameled wire according to claim 3, characterized in that: The slider (7) is externally slidably connected to the inside of the groove (9), and the sliding block (10) is externally slidably connected to the inside of the fixed frame (11).
8. A precision winding device for preventing breakage of fine enameled wire according to claim 3, characterized in that: The mounting frame (12) is slidably connected to the outside of the fixed frame (11) on one side, and the connecting frame (14) is fixedly connected to the bottom of the unwinding roll (13) on one side.
9. A precision winding device for preventing breakage of fine enameled wire according to claim 4, characterized in that: The inside of the tensioning wheel (15) is in contact with the outside of the arc block (17), and the outside of the fixing rod (16) is in contact with the outside of the arc plate (22).
10. A precision winding device for preventing breakage of fine enameled wire according to claim 4, characterized in that: One end of the spring (21) is fixedly connected to the bottom of the arc plate (22), and the other end of the spring (21) is fixedly connected to the top of the fixed plate (18).