A method for surface full-coverage coil winding of regular and irregular ferromagnetic bodies

Abstract

This invention discloses a method for fully covering the surface of regular and irregular ferromagnetic materials with coil winding, belonging to the field of electromagnetic coil manufacturing technology. The core steps of this method include: S1 Axis Determination: Obtaining the geometric shape of the ferromagnetic material to be wound, and determining a rotation axis that is not perpendicular to any of the outer surfaces of the ferromagnetic material; S2 Clamping and Positioning: Using the two axial endpoints of the rotation axis as support points, fixing the ferromagnetic material on a rotation drive device, making the rotation axis vertical and perpendicular to the horizontal plane; S3 Wire Preparation: Placing the spool with copper wire wound horizontally, making the direction of the copper wire exit parallel to the horizontal plane, and fixing the starting end of the copper wire horizontally at the lowest axial end of the ferromagnetic material; S4 Rotation and Winding: Starting the rotation drive device, driving the ferromagnetic material to rotate uniformly around the rotation axis, so that the copper wire is wound layer by layer evenly around the entire outer surface of the ferromagnetic material. This invention completely solves the problem of winding dead angles in traditional winding methods, achieving full surface coverage without dead angles. It is highly versatile, simple to operate, and low in cost, suitable for coil winding of various regular and irregular ferromagnetic materials, and especially suitable for university research and small-batch customized production scenarios.

Description

Technical Field

[0001] This invention belongs to the field of electromagnetic coil manufacturing technology, specifically relating to a method for winding coils that fully cover the surface of regular and irregular ferromagnetic materials. Background Technology

[0002] Electromagnetic coils are the core components of various electromagnetic devices such as motors, transformers, inductors, electromagnetic actuators, and magnetic field generators. The surface coverage, winding uniformity, and fit with ferromagnetic materials of the coil directly determine the core performance of electromagnetic devices, such as energy conversion efficiency, magnetic field uniformity, and operational stability.

[0003] In the prior art, coil winding methods and equipment are mainly designed for regular-shaped ferromagnetic materials / cores, such as toroidal, E-type, U-type, cylindrical and other standard cores. They usually adopt axial winding or radial winding fixing methods, relying on the geometric symmetry axis of the magnet as the rotation axis, and can only achieve continuous winding of regular planes / curved surfaces.

[0004] For irregularly shaped ferromagnets, such as irregularly shaped permanent magnets, asymmetric magnetic cores, and ferromagnetic components with complex curved / convex / concave structures, existing technologies suffer from the following insurmountable technical defects: Inability to achieve full-surface coverage without dead angles: The rotation axis of traditional winding methods is usually perpendicular to part of the ferromagnetic surface. During rotation, the trajectory of such surfaces remains parallel to the wire output direction, preventing the copper wire from effectively adhering and winding, resulting in permanent winding dead angles and failing to meet the requirement of full-surface coverage; Poor winding uniformity: For asymmetric curved surfaces and irregularly shaped structures, traditional methods are prone to problems such as coil overlap, excessive gaps, loose adhesion, and detachment. Poor coil consistency leads to uneven magnetic field distribution, severely affecting the performance of electromagnetic equipment; high equipment cost and poor adaptability: for winding irregularly shaped parts, existing technology requires customized multi-axis linkage CNC equipment, special molds, guide rails, etc., with a single equipment investment of hundreds of thousands of yuan, and a set of molds can only adapt to one type of ferromagnetic material, resulting in extremely poor flexibility and making it completely unsuitable for university research and customized production scenarios with small batches and multiple varieties; high operating threshold and low efficiency: professional technicians are required to program the winding path, design the mold, and debug the equipment, resulting in a long preparation period, extremely low winding efficiency for a single batch of products, and inability to quickly adapt to different shapes of ferromagnetic materials.

[0005] Therefore, there is an urgent need to develop a universal, simple, and low-cost method for uniform coil winding on the entire surface of both regular and irregular ferromagnetic materials, so as to completely solve the pain points of existing technologies. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of existing technologies, such as incomplete coverage of irregular ferromagnetic materials, dead corners, poor uniformity, complex equipment, high cost, and poor adaptability. This invention provides a method for winding coils that fully cover the surface of regular and irregular ferromagnetic materials, achieving uniform winding of all types of ferromagnetic materials without dead corners, and significantly reducing the winding threshold and cost.

[0007] (I) Technical Solution

[0008] To achieve the above objectives, the present invention adopts the following technical solution: a method for fully covering the surface of regular and irregular ferromagnetic materials with coil winding, comprising the following steps:

[0009] S1 Axis Determination: Obtain the geometric shape of the ferromagnetic body to be wound, and determine a rotation axis that is not perpendicular to all the outer surfaces of the ferromagnetic body;

[0010] S2 clamping and positioning: Using the two axial endpoints of the rotation axis as support points, the ferromagnet is fixed on the rotation drive device, and the rotation axis is made vertical and perpendicular to the horizontal plane;

[0011] S3 Wire laying preparation: Place the spool with copper wire wound horizontally, so that the direction of the copper wire exit is parallel to the horizontal plane, and fix the starting end of the copper wire horizontally at the lowest position of the axial direction of the ferromagnet.

[0012] S4 Rotary Winding: Start the rotary drive device to drive the ferromagnet to rotate at a constant speed around the rotation axis, so that the copper wire is wound evenly layer by layer on the entire outer surface of the ferromagnet, completing the full-coverage coil winding.

[0013] Further, in step S1, the method for obtaining the geometric shape of the ferromagnetic body to be wound and determining the axis of rotation is a three-dimensional model determination method. Specifically, this involves obtaining a complete three-dimensional digital model of the ferromagnetic body to be wound through three-dimensional scanning or three-dimensional modeling, extracting the normal vectors of all outer surfaces in the model, calculating the angle between the candidate axes and each normal vector, and selecting the axis whose angle with all normal vectors is not 90° as the final axis of rotation. Further, in step S1, the method for obtaining the geometric shape of the ferromagnetic body to be wound and determining the axis of rotation is a visual determination method. Specifically, this involves observing the overall shape of the ferromagnetic body to be wound with the naked eye, marking the two diagonal endpoints of the ferromagnetic body, confirming that the straight line connecting the two endpoints is not perpendicular to any exposed surface of the ferromagnetic body, and using this straight line as the axis of rotation. This method is suitable for the rapid positioning of ferromagnetic bodies with simple shapes.

[0014] Furthermore, in step S2, the two axial endpoints of the rotation axis are fixedly connected to the rotation drive device via the upper and lower support components, respectively. After clamping, all outer surfaces of the ferromagnetic material are suspended and unobstructed, ensuring no blind spots during the winding process. Furthermore, in step S3, the copper wire maintains a constant tension during the unwinding process via a tension adjustment mechanism. The tension range is 0.5N to 5N, with the specific value adjusted according to the copper wire diameter and the external dimensions of the ferromagnetic material.

[0015] Furthermore, in step S3, the exit height of the copper wire is at the same horizontal level as the fixed position of the lowest point of the ferromagnetic body along its axis, ensuring that the starting end of the copper wire is fixed horizontally without any tilt angle.

[0016] Furthermore, in step S4, the rotational speed of the rotary drive device is 10 r / min to 60 r / min, maintaining a uniform speed without fluctuations during rotation. Furthermore, in step S4, during the winding process, the copper wire spool moves synchronously and uniformly upwards along the vertical direction of the rotation axis, with the upward speed matching the rotational speed to ensure that the copper wires are evenly distributed layer by layer without overlap or gaps.

[0017] Furthermore, the ferromagnetic material to be wound includes any one of the following: ferromagnetic materials with regular geometric shapes, asymmetrical irregular ferromagnetic materials, ferromagnetic components with concave and convex surfaces, permanent magnets, and soft magnetic cores.

[0018] (ii) Beneficial effects

[0019] Compared with the prior art, the present invention has the following advantages:

[0020] (1) Completely solve the dead angle of winding and achieve full surface coverage without dead angle: The core innovation of this invention is that by selecting a rotation axis that is not perpendicular to all the outer surfaces of the ferromagnet, it is ensured that when the ferromagnet rotates around the axis, the angle between the normal vector of all the outer surfaces and the rotation axis is not 90°. During the rotation, all areas of each surface can form an effective contact angle with the horizontally exiting copper wire, which completely solves the problem of dead angle of winding in the traditional method and achieves 100% full coverage of the outer surface of the ferromagnet.

[0021] (2) Extremely universal and adaptable to all types of ferromagnets: This invention does not require custom molds, programming or special equipment for the shape of ferromagnets. It can be directly applied to regular cubes, cylinders, cones, or irregular ferromagnets with asymmetry, complex curved surfaces and concave and convex structures, which greatly improves the adaptability of the winding method and is especially suitable for multi-category, small-batch experimental scenarios in university scientific research.

[0022] (3) Good winding uniformity and stable electromagnetic performance: Through uniform rotation and horizontal constant tension wire release, the copper wire can be uniformly attached to the surface of the ferromagnetic body layer by layer, which fundamentally avoids the problems of coil overlap, excessive gap and loosening. The coil arrangement is consistent and can form a uniform and stable magnetic field, effectively improving the performance stability of the electromagnetic equipment.

[0023] (4) The equipment has a simple structure and extremely low cost: This invention only requires a conventional rotary drive device, without the need for a multi-axis linkage CNC system, special molds or guide rails. The equipment investment is less than 1 / 10 of that of traditional irregular winding equipment. It can be quickly set up in ordinary laboratories, with a very low operating threshold. Students can complete the operation independently after simple training.

[0024] (5) High winding efficiency and adaptable to rapid testing needs: No complicated path planning or mold preparation is required. Only three core steps are needed: determining the axis of rotation, clamping and fixing, and starting rotation. The winding efficiency of a single batch of products is more than 5 times higher than that of traditional irregular winding methods. It can quickly adapt to the testing and production needs of ferromagnetic materials of different shapes. Attached Figure Description

[0025] Figure 1 Flowchart of the steps of the method for fully covering the surface of regular and irregular ferromagnetic materials with coil winding according to the present invention;

[0026] Label Explanation:

[0027] S1—Axis Determination: The axis of rotation of the ferromagnetic body is determined visually;

[0028] S2—Clamping and Positioning: Use a special clamp to fix the position of the ferromagnet;

[0029] S3—Wire preparation: Lead the coil out of the reel and fix the starting end;

[0030] S4—Rotary Winding: The ferromagnet is fixed by a clamp and rotated clockwise at a uniform speed, and the coil is tightly wound to cover the entire surface.

[0031] Figure 2 A schematic diagram illustrating the geometric relationship between the axis of rotation and the surface of the ferromagnetic material in this invention.

[0032] Reference numerals: 1-Ferromagnetic body; 2-Rotation axis (in this invention); 3-Surface normal vector; 4-Comparison axis (conventional method); 5-Wrapping dead angle area.

[0033] Figure 3 Schematic diagram of the rotation axis positioning of the regular cubic ferromagnetic body in Embodiment 1 of the present invention

[0034] Labeling explanations: 1-Cube ferromagnet; 2-Axis of rotation; 6-Upper support point; 7-Lower support point

[0035] Figure 4 Schematic diagram of the rotation axis positioning of the irregularly shaped ferromagnetic body in Embodiment 2 of the present invention

[0036] Labeling explanations: 1-Irregular ferromagnetic body; 2-Axis of rotation; 6-Upper support point; 7-Lower support point; 8-Protruding structure

[0037] Figure 5 Overall structural diagram of the winding device of the present invention

[0038] Labeling Explanation: 1- Ferromagnetic body to be wound; 2- Rotation axis; 3- Rotation drive device; 4- Upper support assembly; 5- Lower support assembly; 6- Copper wire spool; 7- Copper wire; 8- Tension adjustment mechanism; 9- Fixing frame; 10- Rotation drive motor Detailed Implementation

[0039] The present invention will be further described in detail below with reference to specific embodiments.

[0040] The core principle of this invention is as follows: If the angle between the normal vector of any outer surface of a ferromagnetic material and the axis of rotation is 90° (i.e., the axis is perpendicular to the surface), then when the surface rotates around the axis, its trajectory is always parallel to the horizontally extending copper wire, and the copper wire cannot adhere to and wrap around the surface, forming a dead angle for winding. This invention ensures that the angle between the normal vector of any surface and the axis of rotation is not 90° by selecting a rotation axis that is not perpendicular to all outer surfaces. During the rotation, all areas of each surface can form an effective contact angle with the horizontally extending copper wire, thereby achieving uniform winding of the entire surface.

[0041] Example 1: Determination of the S1 axis for full-coverage coil winding of a regular cubic ferromagnet: The ferromagnet to be wound is a cubic neodymium iron boron permanent magnet with a side length of 10mm. The rotation axis is determined by visual inspection: Observe the 8 vertices of the cube with the naked eye, select the diagonal endpoints A (0,0,0) and B (10,10,8), connect the two points to form a straight line, and verify that this straight line is not perpendicular to the 6 outer surfaces of the cube (front, back, left, right, top, and bottom): The normal vectors of the 6 surfaces are along the X, Y, and Z axes respectively. The direction vector of this straight line is (10,10,8), and the angle between it and the X, Y, and Z axes is not 90°. Therefore, it is not perpendicular to any of the surfaces, and this straight line is determined as the rotation axis.

[0042] S2 clamping and positioning: Using the two endpoints A and B of the rotation axis as support points, the cubic ferromagnetic body is fixed on the rotating main shaft of the rotation drive device through the insulating clamping fixtures of the upper and lower support components. The clamping position is adjusted so that the rotation axis is completely vertical and perpendicular to the horizontal plane. After clamping, all 6 outer surfaces of the cube are in a suspended and unobstructed state without any clamping obstruction.

[0043] S3 wire preparation: Select 0.2mm diameter enameled copper wire, place the spool with the copper wire wound horizontally on the right side of the ferromagnet, the copper wire exits through the tension adjustment mechanism and the horizontal guide wheel, the exit direction is parallel to the horizontal plane, and the exit height is at the same level as the lowest point A of the ferromagnet's axis. Fix the starting end of the copper wire horizontally at point A with high-temperature resistant insulating tape, and adjust the tension adjustment mechanism to keep the wire tension at a constant value of 1N.

[0044] S4 Rotary Winding: Start the rotary drive device and set the rotation speed to 30 r / min. Drive the cubic ferromagnet to rotate at a constant speed around the rotation axis. During the rotation, the copper wire spool moves synchronously and uniformly upward along the vertical direction of the rotation axis. The upward speed is set to 6 mm / min to match the rotation speed, so that the copper wire is evenly wound layer by layer on the entire outer surface of the cube. After the winding is completed, cut the copper wire and fix the end to obtain a coil that is evenly covered on the entire surface.

[0045] Upon testing, the coil wound in this embodiment completely covers all six outer surfaces of the cube, with no dead corners, uniform coil arrangement, no overlap or gaps, and tight adhesion to the ferromagnetic surface, fully meeting the usage requirements.

[0046] Example 2: Determination of the S1 Axis for Coil Winding of Irregularly Shaped Ferromagnetic Objects: The ferromagnetic object to be wound is an irregularly shaped soft ferrite core with a single-sided protrusion structure. Its shape is asymmetrical. The rotation axis is determined using a three-dimensional model: A complete three-dimensional digital model of the irregularly shaped ferromagnetic object is obtained using a 3D scanner, imported into 3D modeling software, and the normal vectors of all outer surfaces are extracted. The software iterates through and calculates the angles between candidate axes and each normal vector, selecting an axis whose angle with all normal vectors is not 90°. This axis passes through the two diagonal endpoints of the irregularly shaped ferromagnetic object and is not perpendicular to any of the outer surfaces; this axis is determined as the rotation axis. S2 Clamping and Positioning: Using the two axial endpoints of the rotation axis as support points, the irregularly shaped ferromagnetic object is fixed to the rotating spindle of the rotary drive device using a customized insulated pin-type clamping fixture. The clamping position is adjusted so that the rotation axis is completely vertical and perpendicular to the horizontal plane. After clamping, all outer surfaces of the irregularly shaped ferromagnetic object (including all surfaces with protrusion structures) are suspended and unobstructed, without any clamp obstruction. S3 wire preparation: Select 0.1mm diameter enameled copper wire, place the spool with the copper wire wound horizontally on the left side of the ferromagnet, the copper wire exits through the tension adjustment mechanism and the horizontal guide wheel, the exit direction is parallel to the horizontal plane, and the exit height is at the same horizontal plane as the fixed position at the lowest point of the ferromagnet's axis. Fix the starting end of the copper wire horizontally to the preset position at the lowest point of the ferromagnet by welding, and adjust the tension adjustment mechanism to keep the wire tension at a constant value of 0.5N.

[0047] S4 Rotary Winding: Start the rotary drive device and set the rotation speed to 20 r / min. Drive the irregular ferromagnetic body to rotate at a constant speed around the rotation axis. During the rotation, the copper wire shaft moves synchronously and uniformly upward along the vertical direction of the rotation axis. The upward speed is set to 2 mm / min to match the rotation speed, so that the copper wire is wound evenly layer by layer on the entire outer surface of the irregular ferromagnetic body, including all surfaces of the protruding structure. After the winding is completed, cut the copper wire and fix the end to obtain a coil with uniform coverage of the entire surface.

[0048] Upon testing, the coil wound in this embodiment completely covers all the outer surfaces of the irregular ferromagnetic material, including the curved and vertical surfaces of the raised structure, with no dead corners in the winding. The coils are evenly arranged, without overlap or loosening, and the magnetic field uniformity is improved by more than 40% compared with the traditional winding method.

[0049] Example 3: Coil winding covering the entire surface of a conical ferromagnetic body

[0050] The ferromagnet to be wound is a conical permanent magnet with a bottom diameter of 20mm and a height of 30mm. The method of visual determination is used to select a point on the edge of the bottom surface of the cone and a diagonal point on the edge of the top surface of the cone. The two points are connected to form a rotation axis. It is verified that this axis is not perpendicular to the bottom and side surfaces of the cone. After clamping, the magnet is rotated and wound around this axis to achieve uniform coverage of the entire surface of the bottom and side surfaces of the cone without any dead corners.

[0051] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for winding a coil to fully cover the surface of regular and irregular ferromagnetic materials, characterized in that, Includes the following steps: S1. Axis Determination: Obtain the geometry of the ferromagnetic body to be wound, and determine a rotation axis that passes through the ferromagnetic body and is not perpendicular to any of the outer surfaces of the ferromagnetic body; S2. Clamping and positioning: Using the two axial endpoints of the rotation axis as support points, fix the ferromagnetic body on the rotation drive device and keep the rotation axis vertical; S3. Wire laying preparation: Place the spool horizontally so that the direction of the copper wire exit is parallel to the horizontal plane, and fix the starting end of the copper wire at the lowest axial end of the ferromagnetic body; S4. Rotation and winding: Start the rotation drive device to drive the ferromagnet to rotate at a constant speed around the rotation axis, so that the copper wire is wound layer by layer evenly around the entire outer surface of the ferromagnet under the action of gravity and tension.

2. The winding method according to claim 1, characterized in that, In step S1, the method for determining the axis of rotation includes: selecting the central axis of the geometry of the ferromagnetic body, or selecting any straight line that passes through the center of gravity of the ferromagnetic body and is not perpendicular to its surface as the axis of rotation.

3. The winding method according to claim 1, characterized in that, In step S2, the rotary drive device includes a main shaft and a driven center, and the ferromagnetic body is fixed by engaging with the main shaft and the driven center at its two axial ends respectively.

4. The winding method according to claim 1, characterized in that, In step S3, the starting end of the copper wire is fixed to the lowest axial end of the ferromagnet by means of insulating tape or welding.

5. The winding method according to claim 1, characterized in that, In step S4, the rotational speed range of the rotary drive device is 5-60 revolutions per minute.

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