A coil winding device for transformer production and processing

Abstract

This invention discloses a coil winding device for transformer manufacturing, comprising a frame. The top of the frame, along the copper wire conveying direction, is sequentially equipped with a copper wire wheel clamping mechanism, a twisting mechanism, a moving mechanism, and a core fixing mechanism. The copper wire wheel clamping mechanism can clamp multiple copper wire wheels, and multiple strands of copper wire intertwine when the clamping mechanism rotates. The twisting mechanism twists the wound copper wire. The moving mechanism moves the twisted copper wire according to its trajectory. The core fixing mechanism positions and clamps the core, and rotates synchronously with the core fixing mechanism when it rotates. This invention significantly improves the tightness and uniformity of coil winding through an integrated synchronous clamping and twisting mechanism, and achieves efficient automation of the winding process and precise adaptation to cores of different specifications through precise movement control and an adaptive clamping system.

Description

Technical Field

[0001] This invention relates to the field of transformer manufacturing technology, and in particular to a coil winding device for transformer production and processing. Background Technology

[0002] Transformers are important electromagnetic devices in electrical engineering and are widely used in power systems, electronic equipment and other fields. The main components of a transformer include the core, windings and insulation materials. Among them, the windings are the key components of a transformer, and their performance directly affects the transformer's efficiency, losses and reliability.

[0003] Existing winding equipment, such as the coil winding device and processing method for transformer manufacturing shown in authorization announcement number CN118609987B, involves winding a single copper wire around an iron core. However, when winding the copper wire around the iron core, it is often not a single strand but multiple strands of copper wire. If multiple strands of copper wire are wound around the iron core sequentially, the loose strands are prone to unraveling, crossing, and knotting during winding, especially when the number of turns is large and the wire diameter is thin, making operation difficult. At the same time, the effect on reducing high-frequency losses is limited because the position of each strand in the magnetic field is fixed. The outer strands have less magnetic flux and lower inductance, while the inner strands have more magnetic flux and higher inductance. This results in uneven current distribution among the strands (larger current in the outer layer and smaller current in the inner layer), making it impossible to fully utilize all conductors, and the proximity effect loss remains severe.

[0004] Therefore, this application provides a coil winding device for transformer manufacturing and processing. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a coil winding device for transformer production and processing. This invention significantly improves the tightness and uniformity of coil stranding through an integrated synchronous clamping and twisting mechanism, and achieves efficient automation of the winding process and precise adaptation to iron cores of different specifications by means of precise movement control and adaptive clamping system.

[0006] This invention is achieved through the following technical solution: This invention discloses a coil winding device for transformer production and processing, including a frame, and the top of the frame is sequentially equipped with a copper wire wheel clamping mechanism, a twisting mechanism, a moving mechanism and an iron core fixing mechanism along the copper wire conveying direction; The copper wire wheel clamping mechanism can clamp multiple copper wire wheels, and multiple strands of copper wire are intertwined when the copper wire wheel clamping mechanism rotates; The twisting mechanism can twist the wound copper wire; The moving mechanism enables the twisted copper wire to move along the movement trajectory of the moving mechanism; The core fixing mechanism can position and clamp the core, and the core rotates synchronously with the core fixing mechanism when the core fixing mechanism rotates.

[0007] Furthermore, the copper wire wheel clamping mechanism includes a gear ring rotatably connected to the frame, a cross-shaped fixing plate fixed to the inner side of the gear ring, and a plurality of U-shaped copper wire wheel placement frames distributed circumferentially along the cross-shaped fixing plate. The two ends of the U-shaped copper wire wheel placement frames are provided with fasteners for clamping the copper wire wheels, and the cross-shaped fixing plate is provided with copper wire through holes corresponding to the U-shaped copper wire wheel placement frames.

[0008] Furthermore, the fastener includes a threaded rod, a handle disposed at one end of the threaded rod, and a tapered clamping head connected to the other end of the threaded rod via a bearing. The U-shaped copper wire wheel placement frame has threaded grooves at both ends that are adapted to the threaded rod.

[0009] Furthermore, a drive motor three is mounted on the frame, and the output end of the drive motor three is connected to a gear two that meshes with the gear ring.

[0010] Furthermore, the twisting mechanism includes a fixed frame fixed to the frame, a copper wire guide hole in the middle of the fixed frame, and a sliding groove three on both the upper and lower sides of the fixed frame of the copper wire guide hole. A twisting block is slidably connected in each sliding groove three, and two twisting blocks are arranged opposite to each other.

[0011] Furthermore, each of the twisting blocks is connected to a rotating rod, the middle of which is hinged to the fixed frame. The two rotating rods are connected by two hinged rods that are hinged to each other. One of the rotating rods is hinged to an electric telescopic rod at its end, and the cylinder of the electric telescopic rod is hinged to the fixed frame.

[0012] Furthermore, the moving mechanism includes a reciprocating lead screw rotatably connected to the frame, a lead screw slider threadedly engaged with the reciprocating lead screw, and a guide rod fixed below the reciprocating lead screw. The lead screw slider has a through hole for the guide rod to pass through, and two guide wheels are symmetrically arranged on the inner side of the top of the lead screw slider.

[0013] Furthermore, a second drive motor for driving the reciprocating lead screw to rotate is mounted on the frame.

[0014] Furthermore, the core fixing mechanism includes a rotating disk rotatably connected to the frame, two relatively sliding fixed plates on one side of the rotating disk, a gear on the rotating disk, and two racks meshing with the gear being fixedly connected to the inner sides of the two fixed plates respectively.

[0015] Furthermore, the rack is slidably disposed in a second slide groove, the end of the fixing plate is slidably disposed in a first slide groove, and a drive motor for driving the rotating disk is mounted on the frame.

[0016] The present invention has the following advantages: (1) The present invention achieves one-time synchronous and secure clamping of multiple copper wire wheels through the copper wire wheel clamping mechanism, and the unified rotation drive enables multiple copper wires to complete the initial stranding continuously and synchronously, eliminating the cumbersome steps of separate guidance and pre-stranding in the traditional process. The subsequent twisting mechanism dynamically compacts and kneads the initially stranded wire bundle through precise mechanical action, effectively eliminating the loose gaps between the strands, making the cross-section of the stranded copper wire more regular and the structure more compact. This lays a solid material foundation for the subsequent winding of a tight and uniform coil, and directly improves the electrical performance and mechanical stability of the coil.

[0017] (2) This invention guides the copper wire to move back and forth along the iron core axis at a uniform speed and smoothly through the precise transmission of the reciprocating screw via a moving mechanism. This ensures that each layer of winding is evenly distributed and neatly arranged, avoiding the problem of uneven density caused by manual operation. At the same time, the iron core fixing mechanism, through ingenious gear and rack transmission, can drive the clamping components to smoothly and synchronously extend and retract, thereby quickly and firmly clamping iron cores of different specifications and sizes. This not only ensures the absolute stability of the iron core during high-speed rotating winding, but also greatly enhances the equipment's adaptability to different product models. The entire system, from copper wire preparation and processing to final winding, forms a continuous, coordinated, and highly automated process. While ensuring the accuracy and consistency of coil winding, it significantly reduces labor intensity and dependence on operator skills. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall first-view structure of the present invention; Figure 2 This is a schematic diagram of the overall second-view structure of the present invention; Figure 3 This is a schematic diagram of the overall structure of the copper wire wheel clamping mechanism of the present invention; Figure 4 This is a schematic diagram of the internal structure of the frame of the present invention; Figure 5 This is a schematic diagram of the overall structure of the twisting mechanism of the present invention; Figure 6 This is a schematic diagram of the overall structure of the moving mechanism of the present invention; Figure 7 This is a schematic diagram of the overall structure of the iron core fixing mechanism of the present invention.

[0019] In the diagram: 100, Frame; 200, Core fixing mechanism; 201, Drive motor one; 202, Rotary disk; 203, Fixing plate; 204, Slide one; 205, Slide two; 206, Rack; 207, Gear one; 300, Moving mechanism; 301, Drive motor two; 302, Lead screw and slider; 303, Reciprocating lead screw; 304, Guide wheel; 305, Guide rod; 400, Twisting mechanism; 401 402. Fixed frame; 403. Electric telescopic rod; 404. Rotating rod; 405. Hinge rod; 406. Twisting block; 407. Slide groove three; 408. Copper wire guide hole; 509. Copper wire wheel clamping mechanism; 500. Drive motor three; 501. Gear two; 502. Gear ring; 503. U-shaped copper wire wheel placement frame; 504. Fastener; 505. Copper wire wheel; 506. Copper wire through hole; 507. Cross-shaped fixing plate. Detailed Implementation

[0020] The embodiments of the present invention are described in detail below. These embodiments are implemented based on the technical solution of the present invention, and provide detailed implementation methods and specific operation processes. However, the scope of protection of the present invention is not limited to the following embodiments. In the description of the present invention, words such as "front", "rear", "left", and "right" that indicate orientation or positional relationship are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0021] Example 1 Example 1 discloses a coil winding device for transformer manufacturing, such as... Figures 1-7 As shown, the system includes a frame 100, on the top of which, from left to right, are sequentially assembled a copper wire wheel clamping mechanism 500, a twisting mechanism 400, a moving mechanism 300, and an iron core fixing mechanism 200. The copper wire wheel clamping mechanism 500 synchronously and stably clamps multiple copper wire wheels, and during the rotation of the copper wire wheel clamping mechanism 500, multiple strands of copper wire are intertwined. Subsequently, the twisting mechanism 400 twists the intertwined copper wire, making the intertwined copper wire more tightly wound, which is convenient for subsequent winding of a uniform coil. The moving mechanism 300 precisely controls the movement path of the tightly wound copper wire, so that the iron core can move along the length direction of the iron core when the copper wire is wound. Finally, the iron core fixing mechanism 200 positions and clamps the iron core, and drives the iron core to rotate so that the copper wire can be wound on the iron core.

[0022] like Figure 2 and Figure 3As shown, in this embodiment, the copper wire wheel clamping mechanism 500 includes a gear ring 503 rotatably connected to the frame 100 via bearings and a cross-shaped fixing plate 508 fixed inside the gear ring 503. A U-shaped copper wire wheel placement frame 504 is fixed at equal intervals on one side of the cross-shaped fixing plate 508 with the gear ring 503 as the center. Fasteners 505 at both ends of the U-shaped copper wire wheel placement frame 504 clamp the copper wire wheels 506, enabling the clamping of multiple copper wire wheels 506. A copper wire through hole 507 is provided on the cross-shaped fixing plate 508 on one side of the U-shaped copper wire wheel placement frame 504, allowing copper wires on the copper wire wheels 506 to pass through. Therefore, after clamping the copper wire wheels 506, the copper wires pass through the copper wire through hole 507, and during the rotation of the gear ring 503, multiple strands of copper wire can be wound, achieving the initial winding effect of multiple strands of copper wire.

[0023] Furthermore, in this embodiment, a drive motor 3 501 is installed on one side of the frame 100, and a gear 2 502 that meshes with the gear ring 503 is connected to the output end of the drive motor 3 501, so that the drive motor 3 501 drives the gear 2 502 to rotate while driving the gear ring 503 to rotate during operation.

[0024] Furthermore, in this embodiment, the fastener 505 consists of a threaded rod and handles and conical clamping heads respectively disposed at both ends of the threaded rod. The conical clamping head is connected to the end of the threaded rod through a bearing, and threaded grooves adapted to the threaded rod are opened at both ends of the U-shaped copper wire wheel placement frame 504. When the handle is rotated, the threaded rod is driven to move in the threaded groove, and the conical clamping head is inserted into the through hole at the end of the copper wire wheel 506, thereby clamping and fixing the inner wall of the copper wire wheel.

[0025] like Figure 4 and Figure 5As shown, in this embodiment, the twisting mechanism 400 includes a fixed frame 401 fixed inside the frame 100, and a copper wire guide hole 407 is provided at the middle position of the fixed frame 401 to allow the wound copper wire to pass through. Through grooves 406 are provided on both the upper and lower ends of the fixed frame 401 at the copper wire guide hole 407, and twisting blocks 405 are slidably connected in each groove 406. The copper wire passing through the copper wire guide hole 407 is twisted by the two symmetrically arranged twisting blocks 405, making the wound copper wire more tightly wound, facilitating subsequent winding. The coil is uniformly wound, and a rotating rod 403 is vertically mounted at one end of the twisting block 405 and hinged to the fixed frame 401. Two hinged rods 404 are respectively hinged to the ends of the twisting blocks 405 on the upper and lower sides. An electric telescopic rod 402 is installed on the other side of the rotating rod 403, and the output end of the electric telescopic rod 402 is hinged to the rotating rod 403. During the extension and retraction process, the electric telescopic rod 402 drives the rotating rod 403 to rotate along the axis set at its center, thereby driving the upper and lower twisting blocks 405 to move relative to each other to complete the twisting, so as to realize the twisting of multiple copper wires.

[0026] like Figure 4 and Figure 6 As shown, in this embodiment, the moving mechanism 300 includes a reciprocating lead screw 303 rotatably connected to the inner side of the frame 100 and a lead screw slider 302 that can slide on the reciprocating lead screw 303. A guide rod 305 is fixed horizontally below the reciprocating lead screw 303, and a through hole is opened on the lead screw slider 302 that can slide along the guide rod 305. A second drive motor 301 for driving the reciprocating lead screw 303 to rotate is installed on one side of the frame 100, so that the second drive motor 301 can drive the reciprocating lead screw 303 to rotate when it is working, so that the lead screw slider 302 can move back and forth along the reciprocating lead screw 303 during the rotation of the reciprocating lead screw 303. At the same time, guide wheels 304 are symmetrically arranged on the inner side of the top of the lead screw slider 302, so that the twisted copper wire passes through the two guide wheels 304.

[0027] like Figure 4 and Figure 7As shown, in this embodiment, the core fixing mechanism 200 includes a rotating disk 202 rotatably connected to the inner side of the frame 100 and fixed plates 203 symmetrically arranged on one side of the rotating disk 202 that slide relative to each other. A gear 207 is located at the center of one side of the rotating disk 202, and racks 206 meshing with the gear 207 are arranged on its upper and lower sides. One end of each rack 206 is fixed to the inner side of one of the two fixed plates 203, so that when the gear 207 rotates, it can drive the upper and lower racks 206 to slide relative to each other, causing the two fixed plates 203 to slide synchronously. The rack 206 is contracted or expanded to achieve stable clamping of the iron core. During this process, a second groove 205 is provided on one side of the rack 206, which allows the rack 206 to slide along its interior. At the same time, a first groove 204 is fixed at the end of the fixing plate 203, which allows the fixing plate 203 to slide along its interior. A first drive motor 201 for driving the rotating disk 202 to rotate is installed on the outside of the frame 100. When the first drive motor 201 rotates, it synchronously drives the rotating disk 202 and the first gear 207, thereby realizing that the two symmetrically arranged fixing plates 203 can synchronously contract or expand to adapt to iron cores of different sizes.

[0028] In this embodiment, during operation: multiple copper wire spools 506 are placed into the U-shaped placement frame 504 respectively. By rotating the handle of the fastener 505, the conical clamping head at its end can be driven to rotate inward, thereby firmly pressing against the inner wall of the copper wire spool 506, achieving stable mounting of the multiple spools 506. Subsequently, the copper wires led out from each spool pass through the corresponding copper wire through holes 507 on the cross-shaped fixing plate 508 and converge at one place. When the drive motor 501 is started, it drives the outer gear ring 503 to rotate slowly through gear meshing. The cross-shaped fixing plate 508 and all the spools revolve synchronously. This rotational movement causes the converged multiple strands of copper wire to naturally coil around each other, forming a preliminary twist, laying the foundation for subsequent processing.

[0029] The initially twisted copper wire first enters the twisting mechanism 400, passing through its copper wire guide hole 407. With the reciprocating extension and retraction of the electric telescopic rod 402, the upper and lower twisting blocks 405 are driven by the cooperation between the rotating rod 403 and the hinge rod 404 to perform regular relative opening and closing movements along the slide groove 406, twisting and compacting the passing copper wire bundle, making its twisted structure tighter and its appearance smoother. The twisted copper wire then passes between a pair of guide wheels 304 on the lead screw slider 302 inside the moving mechanism 300. When the drive motor 301 drives the reciprocating lead screw 303 to rotate, the lead screw slider 302 carries the guide wheels 304... The reciprocating screw 303 performs precise and uniform reciprocating linear motion, thereby accurately guiding the horizontal transport path of the copper wire. At the same time, the iron core fixing mechanism 200 works. Its drive motor 201 drives the two fixing plates 203 to move relative to each other through the meshing of gear 207 and racks 206 on both sides, thereby firmly clamping the iron core from the inside from both ends. Finally, under the rotational drive of the iron core fixing mechanism 200, the iron core rotates at a uniform speed, which, together with the copper wire transport guided by the moving mechanism 300, allows the tightly twisted copper wire to be evenly, tightly and regularly wound layer by layer on the iron core, completing the entire coil winding process.

[0030] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A coil winding device for transformer manufacturing and processing, comprising a frame (100), characterized in that, The top of the frame (100) is sequentially equipped with a copper wire wheel clamping mechanism (500), a twisting mechanism (400), a moving mechanism (300), and an iron core fixing mechanism (200) along the copper wire conveying direction. The copper wire wheel clamping mechanism (500) can clamp multiple copper wire wheels (506), and multiple strands of copper wire are intertwined when the copper wire wheel clamping mechanism (500) rotates; The twisting mechanism (400) is capable of twisting the wound copper wire; The moving mechanism (300) enables the twisted copper wire to move along the movement trajectory of the moving mechanism (300); The core fixing mechanism (200) can position and clamp the core, and the core rotates synchronously with the core fixing mechanism (200) when the core fixing mechanism (200) rotates.

2. The coil winding device for transformer manufacturing and processing as described in claim 1, characterized in that, The copper wire wheel clamping mechanism (500) includes a gear ring (503) rotatably connected to the frame (100), a cross-shaped fixing plate (508) fixed to the inner side of the gear ring (503), and a plurality of U-shaped copper wire wheel placement frames (504) distributed circumferentially along the cross-shaped fixing plate (508). The two ends of the U-shaped copper wire wheel placement frame (504) are provided with fasteners (505) for clamping copper wire wheels (506). The cross-shaped fixing plate (508) is provided with copper wire through holes (507) corresponding to the U-shaped copper wire wheel placement frame (504).

3. The coil winding device for transformer manufacturing and processing as described in claim 2, characterized in that, The fastener (505) includes a threaded rod, a handle at one end of the threaded rod, and a tapered clamping head connected to the other end of the threaded rod via a bearing. The U-shaped copper wire wheel placement frame (504) has threaded grooves at both ends that are adapted to the threaded rod.

4. The coil winding device for transformer manufacturing and processing as described in claim 2, characterized in that, A drive motor three (501) is mounted on the frame (100), and the output end of the drive motor three (501) is connected to a gear two (502) that meshes with the gear ring (503).

5. The coil winding device for transformer manufacturing and processing as described in claim 1, characterized in that, The twisting mechanism (400) includes a fixed frame (401) fixed on the frame (100). The fixed frame (401) has a copper wire guide hole (407) in the middle. The fixed frame (401) on both the upper and lower sides of the copper wire guide hole (407) is provided with a sliding groove (406). A twisting block (405) is slidably connected in each sliding groove (406). The two twisting blocks (405) are arranged opposite to each other.

6. The coil winding device for transformer manufacturing and processing as described in claim 5, characterized in that, Each of the twisting blocks (405) is connected to a rotating rod (403), the middle part of which is hinged to the fixed frame (401). Two rotating rods (403) are connected by two hinged rods (404). One of the rotating rods (403) is hinged to an electric telescopic rod (402) at its end. The cylinder of the electric telescopic rod (402) is hinged to the fixed frame (401).

7. The coil winding device for transformer manufacturing and processing as described in claim 1, characterized in that, The moving mechanism (300) includes a reciprocating lead screw (303) rotatably connected to the frame (100), a lead screw slider (302) threadedly engaged with the reciprocating lead screw (303), and a guide rod (305) fixed below the reciprocating lead screw (303). The lead screw slider (302) has a through hole for the guide rod (305) to pass through, and two guide wheels (304) are symmetrically arranged on the inner side of the top of the lead screw slider (302).

8. The coil winding device for transformer manufacturing and processing as described in claim 7, characterized in that, The frame (100) is equipped with a second drive motor (301) for driving the reciprocating lead screw (303) to rotate.

9. A coil winding device for transformer manufacturing and processing as described in claim 1, characterized in that, The core fixing mechanism (200) includes a rotating disk (202) rotatably connected to the frame (100). Two relatively sliding fixing plates (203) are provided on one side of the rotating disk (202). A gear (207) is provided on the rotating disk (202). Two racks (206) meshing with the gear (207) are fixedly connected to the inner sides of the two fixing plates (203) respectively.

10. A coil winding device for transformer manufacturing and processing as described in claim 9, characterized in that, The rack (206) is slidably disposed in a second slide groove (205), the end of the fixing plate (203) is slidably disposed in a first slide groove (204), and a drive motor (201) for driving the rotating disk (202) to rotate is installed on the frame (100).

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