A magnetic ring inductor automatic assembly production line and a production process thereof

Abstract

The application discloses a kind of magnetic ring inductance automatic assembly production line and production process, it is related to magnetic ring inductance production technical field, the production line includes transport unit, first branch unit, chamfer unit, soldering unit and second branch unit.The first branch unit includes limit pawl and the branch plate of horizontal movement, for the four pins of magnetic ring inductance are evenly separated to two sides;The chamfer unit is used to chamfer the end of pin processing;The soldering unit is used to the soldering processing of pin;The second branch unit is used to the secondary branch or shaping of pin, by full-automatic branch, chamfer and soldering treatment, ensure the uniformity and precision of pin spacing, avoid burr and sharp edge problem, improve the cooperation quality of pin and base;Simultaneously, through the collaborative design of base mounting unit and partition plate mounting unit, realize the automatic assembly of base and winding copper column and the accurate insertion of partition plate, improve product consistency and production efficiency.

Description

Technical Field

[0001] This invention relates to magnetic ring inductor manufacturing technology, and more particularly to an automated assembly line for magnetic ring inductors and its manufacturing process. Background Technology

[0002] As an indispensable basic component in electronic circuits, magnetic ring inductors are widely used in power management, signal filtering, and impedance matching. The stability of their electrical performance and the reliability of their mechanical structure directly determine the quality of the final electronic products. A typical magnetic ring inductor usually includes a magnetic core frame, wire-wound copper pillars, and multiple leads, and needs to be packaged with a base, partitions, and other components to complete the overall encapsulation.

[0003] Currently, the manufacturing of magnetic ring inductors still mainly relies on a combination of semi-automated equipment and manual operation. In particular, in key processes such as pin processing, base assembly, and partition installation, existing processes and equipment have the following technical defects:

[0004] As a crucial component for the electrical connection between the magnetic ring inductor and the circuit board, the pins' length consistency, end shape, and spacing accuracy have a decisive impact on subsequent insertion processes and soldering quality. However, in current manufacturing technologies, pins commonly exhibit inconsistent lengths and residual burrs at the ends after molding. On one hand, the lack of high-precision cutting and online inspection methods results in large pin length tolerances, easily leading to issues like unevenness or poor soldering after installation. On the other hand, the pin ends are usually not chamfered, and their sharp edges or burrs can easily damage the socket wall when inserted into the base, even causing stress concentration at the pin root and affecting the structural integrity of the copper pillar. Furthermore, the soldering of the pins is mostly done manually using a dip-soldering method, making it difficult to control the solder layer thickness and easily leading to quality problems such as uneven soldering and bridging short circuits.

[0005] The four pins of a magnetic ring inductor are initially clustered together and must be evenly separated to a predetermined spacing before the base can be assembled. Currently, the industry commonly uses manual separation with simple fixtures, which has significant drawbacks: First, manual operation cannot guarantee consistent angle and force for each separation, resulting in large fluctuations in pin spacing and making it difficult to meet precision assembly requirements; second, uneven force during separation can easily cause bending or cracking at the pin roots, affecting mechanical strength and conductivity; third, facing the production needs of multiple varieties and small batches, manual separation is difficult to achieve rapid changeover, restricting the flexibility of the production line.

[0006] As the supporting structure for wound-rotor motors, the base has internal sockets that must be inserted one-to-one with the pins. However, existing assembly methods are mostly manual or semi-automatic press-in, which generally have the following problems: First, the alignment of the pins and the base sockets lacks an effective guiding structure, making it easy for the pins to become misaligned during insertion, resulting in the base tilting or the sockets cracking, seriously affecting the product's appearance and electrical performance; second, the clamping stability of the base during assembly is insufficient, making it prone to displacement and making it difficult to ensure assembly consistency; third, the base feeding, positioning, and pressing processes are mostly independent workstations, requiring manual transfer between processes, leading to mismatched production cycles and serious backlog of work-in-process.

[0007] As a key component separating two wound copper pillars, the installation accuracy of the separator directly affects the electromagnetic interference immunity of inductor products. In existing technologies, separator installation is mostly done manually, which presents the following technical challenges: First, the separator is small and irregularly shaped, making it difficult to ensure its vertical orientation during manual placement, easily leading to incomplete insertion into the slot; second, the lack of constant force control during the pushing process means that excessive insertion force can easily damage the separator or slot structure; third, the lack of online detection methods makes it impossible to monitor in real time whether the separator is installed correctly, and missing or partially installed products are prone to flow into the next process, increasing quality risks.

[0008] In conclusion, further improvements are necessary. Summary of the Invention

[0009] Based on the above-mentioned technical problems, this invention proposes an automated assembly line for magnetic ring inductors and its production process.

[0010] The technical solution of this invention is implemented as follows:

[0011] An automated assembly line for magnetic ring inductors, characterized in that it comprises:

[0012] Transport unit, used to transport magnetic ring inductors;

[0013] The first branching unit includes a limiting claw and a horizontally movable branching plate. The limiting claw is used to clamp the winding copper pillar of the magnetic ring inductor, and the branching plate is used to separate the four pins of the magnetic ring inductor to both sides.

[0014] Chamfering unit, used to chamfer the ends of the pins;

[0015] Soldering unit, used for soldering pins;

[0016] The second branching unit is used for secondary branching or reshaping of the pins;

[0017] It also includes a magnetic ring inductor base mounting device, the base mounting device comprising:

[0018] Base transport unit, used for transporting the base;

[0019] The winding copper column transport unit is used to transport the winding copper column.

[0020] The mounting unit includes a clamping plate and a tapered guide groove disposed in the middle of the clamping plate for guiding the pins into the socket of the base;

[0021] It also includes a magnetic ring inductor partition mounting device, the partition mounting device comprising:

[0022] The multi-station turntable unit has multiple installation stations;

[0023] The limiting unit is used to fix the position of the magnetic ring inductor;

[0024] The partition mounting unit includes a vibratory plate, a first hysteresis chamber, a second hysteresis chamber, and a push cylinder, used to insert the partition into the slot of the base.

[0025] A manufacturing process for a magnetic ring inductor, characterized in that the manufacturing process includes:

[0026] Step 1: Perform initial pin splitting through the first splitting unit;

[0027] Step 2: Chamfer the pin ends using the chamfering unit;

[0028] Step 3: Solder the pins using the soldering unit;

[0029] Step 4: Perform secondary branching or reshaping of the pins through the second branching unit.

[0030] In this invention, before Step 1, the magnetic ring inductor is transported to the gripping station by a transport unit and transferred to the first branching unit by a first transfer gripper unit; after Step 4, the steps of inserting the pins into the base and inserting the partition into the base slot are also included.

[0031] The automated assembly line production process for magnetic ring inductors according to the present invention has the following beneficial effects:

[0032] This invention achieves fully automated pin splitting, chamfering, and soldering by setting up a first splitting unit, a second splitting unit, a chamfering unit, and a soldering unit. The combined use of the splitting board and the tapered block ensures the uniformity and accuracy of the pin spacing; the synergistic effect of the V-shaped and pointed parts in the chamfering unit makes the pin ends regular in shape, avoiding burrs and sharp edges, and significantly improving the fit quality between the pins and the base.

[0033] A limiting claw is used to fix the winding copper pillar, and the horizontal movement of the wire separator plate achieves the initial wire separation of the pins. Then, a secondary wire separation is achieved through a conical block and a pusher block, ensuring precise and controllable pin spacing. This process avoids the inconsistencies in angle and force caused by manual operation, eliminates the risk of pin bending or cracking at the root, and improves product consistency and reliability.

[0034] The coordinated design of the base transport unit, the winding copper pillar transport unit, and the installation unit enables automated assembly of the base and the winding copper pillar. The tapered guide groove structure effectively guides the pins for centering and insertion, avoiding damage to the socket and tilting of the base; the stable clamping of the clamping plate ensures positional consistency during assembly, significantly improving the assembly success rate and production efficiency. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the structure of the magnetic ring inductor of the present invention;

[0036] Figure 2 This is a schematic diagram of the structure of the magnetic ring inductor of the present invention;

[0037] Figure 3 This is a schematic diagram of the structure of the magnetic ring inductor wrapping and cutting device of the present invention;

[0038] Figure 4 This is a partial structural schematic diagram of the magnetic ring inductor wrapping and cutting device of the present invention;

[0039] Figure 5 This is a partial structural schematic diagram of the magnetic ring inductor wrapping and cutting device of the present invention;

[0040] Figure 6 This is a schematic diagram of the structure of the first branching unit of the present invention;

[0041] Figure 7 This is a partial structural schematic diagram of the first branching unit of the present invention;

[0042] Figure 8 This is a schematic diagram of the chamfering unit of the present invention;

[0043] Figure 9 This is a schematic diagram of the soldering unit of the present invention;

[0044] Figure 10 This is a partial structural schematic diagram of the magnetic ring inductor wrapping and cutting device of the present invention;

[0045] Figure 11 This is a schematic diagram of the structure of the second branching unit of the present invention;

[0046] Figure 12 This is a schematic diagram of the structure of the magnetic ring inductor base mounting device of the present invention;

[0047] Figure 13This is a schematic diagram of the magnetic ring inductor base mounting device of the present invention from another angle;

[0048] Figure 14 This is a partial structural schematic diagram of the magnetic ring inductor base mounting device of the present invention;

[0049] Figure 15 This is a partial structural schematic diagram of the magnetic ring inductor base mounting device of the present invention;

[0050] Figure 16 This is a partial structural schematic diagram of the magnetic ring inductor base mounting device of the present invention;

[0051] Figure 17 This is a partial structural schematic diagram of the magnetic ring inductor base mounting device of the present invention;

[0052] Figure 18 This is a partial structural schematic diagram of the magnetic ring inductor base mounting device of the present invention;

[0053] Figure 19 This is a schematic diagram of the structure of the magnetic ring inductor partition mounting device of the present invention;

[0054] Figure 20 This is a schematic diagram of the structure of the magnetic ring inductor partition mounting device of the present invention;

[0055] Figure 21 This is a schematic diagram of the structure of the magnetic ring inductor partition mounting device of the present invention;

[0056] Figure 22 This is a schematic diagram of the structure of the magnetic ring inductor partition mounting device of the present invention;

[0057] Figure 23 This is a schematic diagram of the structure of the magnetic ring inductor partition mounting device of the present invention;

[0058] Figure 24 This is a schematic diagram of the structure of the magnetic ring inductor partition mounting device of the present invention;

[0059] Figure 25 This is a schematic diagram of the structure of the magnetic ring inductor partition mounting device of the present invention;

[0060] Figure 26 This is a schematic diagram of the structure of the magnetic ring inductor partition mounting device of the present invention.

[0061] The reference numerals in the attached figures are as follows: 10, magnetic ring inductor; 101, magnetic core frame; 102, winding copper pillar; 103, pin; 104, base; 105, separating protrusion; 106, slot; 107, partition; 11, transport unit; 111, first drive motor; 112, first lead screw structure; 113, transport fixture; 12, first transfer gripper unit; 121, first moving component; 122, first gripper; 13, first branching unit; 131, first slide rail; 132, second drive motor; 133, branching fixture; 134, limiting gripper; 135, branching plate; 14, second transfer gripper unit; 141, second moving component; 142, second gripper; 15, chamfering unit; 151, first bearing plate; 152. Chamfering fixture; 153. V-shaped part; 154. Pointed part; 16. Soldering unit; 161. Second bearing plate; 162. Bearing component; 163. Divider plate; 17. Third transfer gripper unit; 171. Third moving assembly; 172. Third gripper; 18. Second splitting unit; 181. Second slide rail; 182. Splitting module; 183. Drive cylinder; 184. Push block; 185. Splitting block; 186. Conical block; 2-11. Base transport unit; 2-111. Vibratory feeder; 2-112. Transport track; 2-113. Adjusting track; 2-114. Bearing fixture; 2-115. First moving assembly; 2-116. First gripper assembly; 2-12. Winding copper column transport unit; 2 -121, First mounting bracket; 2-122, Rotating arm; 2-123, Second gripper assembly; 2-13, Transfer unit; 2-131, Second mounting bracket; 2-132, Second moving assembly; 2-133, Third gripper assembly; 2-14, Mounting unit; 2-141, Third moving assembly; 2-142, Fixture plate; 2-143, Mounting fixture; 2-144, First cylinder; 2-145, Second cylinder; 2-146, Clamping plate; 2-147, Conical guide groove; 2-15, Conveying unit; 3-11, Transfer gripper unit; 3-111, First mounting bracket; 3-112, First drive assembly; 3-113, First gripper assembly; 3-114, Second gripper assembly; 3-12 3-121 Multi-station turntable unit; 3-122 Second mounting bracket; 3-123 Drive motor; 3-123 Turntable; 3-124 Installation station; 3-13 Limiting unit; 3-131 Third mounting bracket; 3-132 First cylinder; 3-133 Second cylinder; 3-14 Positioning unit; 3-141 Fourth mounting bracket; 3-142 Positioning component; 3-15 Partition mounting unit; 3-151 Vibratory feeder; 3-152 Mounting assembly; 3-153 First hysteresis chamber; 3-154 Second hysteresis chamber; 3-155 Push cylinder; 3-156 Ejector pin; 3-16 Transport unit; 3-161 Fifth mounting bracket; 3-162 Slide rail; 3-163 Blocking cylinder. Detailed Implementation

[0062] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0063] Example 1

[0064] Reference Figures 1 to 2 As shown, the magnetic ring inductor 10 includes a core frame 101, on which a pair of wound copper pillars 102 are mounted, with four leads 103 extending downward from the copper pillars 102. Since the leads 103 of the magnetic ring inductor 10 need to be installed inside the base, they need to be trimmed to ensure consistent length. The magnetic ring inductor 10 includes a core frame 101, on which a pair of wound copper pillars 102 are mounted, with four leads 103 extending downward from the copper pillars 102. The four leads 103 can be trimmed to one side or both sides, with a trimming angle of 30-60°.

[0065] The base 104 includes a separating protrusion 105, which is used to separate the pins 103 between the two wound copper pillars 102. The separating protrusion 105 has a slot 106 in the middle, and a partition 107 is engaged in the slot 106 to separate the two wound copper pillars 102.

[0066] In this embodiment, the wound copper post 102 and its four pins 103 below it need to be inserted into the base 104, and finally, a partition 107 is installed to separate the two wound copper posts 102. Referring to... Figures 2 to 8 As shown, the present invention proposes a magnetic ring inductor base mounting device for mounting the wound copper post 102 to the base 104.

[0067] Furthermore, this embodiment also proposes an automated assembly production line for magnetic ring inductors, including a magnetic ring inductor lead-cutting machine 100, a magnetic ring inductor base mounting machine 200, and a magnetic ring inductor partition mounting machine 300. (See reference...) Figures 3 to 11 As shown, the magnetic ring inductor lead trimming device 100 is used to trim the leads 103 to facilitate subsequent mounting of the base. The magnetic ring inductor lead trimming device 100 includes:

[0068] The transport unit 11 includes a first drive motor 111 connected to a first lead screw structure 112, on which a transport fixture 113 is mounted. The transport fixture 113 is capable of supporting multiple magnetic ring inductors 10.

[0069] The first transfer gripper unit 12 includes a first moving component 121, and a first gripper 122 is slidably connected along the first moving component 121.

[0070] The first branching unit 13 includes a first slide rail 131. A second drive motor 132 is installed at one end of the first slide rail 131. The second drive motor 132 drives the branching fixture 133 to move on the first slide rail 131 through a ball screw structure.

[0071] The wire distribution jig 133 is equipped with a limiting claw 134, which is used to clamp the winding copper post 102 portion on the magnetic ring inductor 10. The limiting claw 134 includes a cylinder and clamping plates controlled by the cylinder to open and clamp on the front and rear sides of the winding copper post 102.

[0072] Below the limiting claw 134 is a branch plate 135 that can move horizontally along the left and right sides of the magnetic ring inductor 10.

[0073] Refer again Figure 6 As shown, the four pins 103 extending downward from the winding copper pillar 102 are inserted into the splitter plate 135. The splitter plate 135 can move along the left and right sides of the magnetic ring inductor 10 to separate the four pins 103 to the left and right sides.

[0074] In this embodiment, multiple magnetic ring inductors are placed on the transport fixture 113. The first drive motor 111 is started, and the transport fixture is driven forward through the first lead screw structure 112 to accurately transport the first magnetic ring inductor to the gripping station.

[0075] The first gripper 122 of the first transfer gripper unit 12 moves along the first moving component 121 to the gripping position, and the first gripper 122 grips the magnetic ring inductor on the transport fixture 113.

[0076] The first gripper 122 places the magnetic ring inductor at the designated position on the distribution jig 133. The cylinder of the limiting gripper 134 actuates, driving its clamping plate to firmly hold the winding copper pillar 102 portion of the magnetic ring inductor from the front-to-back direction, achieving precise positioning and fixation. At this time, the four adjacent pins 103 of the magnetic ring inductor are vertically inserted into the guide groove of the distribution plate 135 located below it. Then, the distribution plate 135 is controlled to move in a direction away from each other, and its guide groove spreads the middle of the pins apart. Because the roots of the pins are fixed by the copper pillar and the limiting gripper, this relative movement forces the originally clustered four pins to evenly separate to the left and right, forming two sets of clearly spaced pins.

[0077] Furthermore, the magnetic ring inductor lead-cutting device 100 proposed in this embodiment also includes:

[0078] The second transfer gripper unit 14 includes a second moving component 141 and a second gripper 142 slidably connected along the second moving component 141. The second gripper 142 is used to sequentially transfer the magnetic ring inductor 10 on the first branching unit 13 to the chamfering unit 15 and the soldering unit 16.

[0079] The chamfering unit 15 includes a first support plate 151, and a chamfering fixture 152 is installed inside the first support plate 151. The chamfering fixture 152 has V-shaped parts 153 that can move relative to each other on both sides, and the chamfering fixture 152 also has pointed parts 154 that cooperate with the V-shaped parts 153 on both sides.

[0080] In this embodiment, the wound copper post 102 to be processed is placed or conveyed to a predetermined position on the chamfering fixture 152. The V-shaped members 153 on both sides of the chamfering fixture 152 move towards each other under the action of a driving mechanism (such as a cylinder), clamping the pin 103 area or body of the wound copper post 102 from both sides. The V-groove design can adapt to pins of different diameters, ensuring that the copper post is accurately and stably positioned at the center of the fixture, preventing displacement during processing.

[0081] Simultaneously or after the V-shaped member 153 clamps, the pointed member 154, mounted on the chamfering fixture 152 and mates with the V-shaped member 153, begins to function. The pointed member 154 typically has a precisely tapered or specifically contoured tip. The mating of the V-shaped member 153 and the pointed member 154 ensures a uniform machining reference. The V-shaped member is responsible for coarse radial positioning and clamping, while the pointed member may provide finer axial guidance or serve as a support reference for the chamfering cutting edge, together ensuring that the four pins 103 have a highly consistent and correct position relative to the chamfering tool.

[0082] The soldering unit 16 includes a second carrier plate 161, and a carrier member 162 is provided in the middle of the second carrier plate 161. The carrier member 162 has a partition plate 163 in the middle of the partition pin 103.

[0083] The third transfer gripper unit 17 includes a third moving component 171 and a third gripper 172 slidably connected along the third moving component 171.

[0084] Below the third transfer gripper unit 17, there is another first branching unit 13 and a second branching unit 18. The second branching unit 18 includes a second slide rail 181, and the second slide rail 181 drives the branching module 182 to move on the second slide rail 181 through a ball screw structure.

[0085] The splitter module 182 includes a splitter block 185, with a conical block 186 in the middle of the splitter block 185. Drive cylinders 183 are provided on both sides of the splitter block 185, and push blocks 184 are provided on the output shaft of the drive cylinders 183.

[0086] In this embodiment, the transport unit 11 is started, and the first drive motor 111 drives the transport fixture 113 forward through the first lead screw structure 112, so as to transport the multiple magnetic ring inductors 10 carried thereon to the designated gripping station in sequence.

[0087] The first gripper 122 of the first transfer gripper unit 12 moves along the first moving assembly 121 to the gripping station and grips the first magnetic ring inductor on the transport fixture. The first gripper transfers the magnetic ring inductor and precisely places it on the branch fixture 133 of the first branch unit 13. The cylinder of the limiting gripper 134 is activated, driving its clamping plate to firmly clamp the winding copper post 102 part of the magnetic ring inductor from the front and back direction, thereby achieving positioning and fixation.

[0088] At this point, four downward-extending and mutually close pins 103 are vertically inserted into the guide slots of the splitter board 135. Under the drive, the splitter board moves horizontally along the left and right sides of the magnetic ring inductor, using the guide slots to evenly spread the four pins from the center to the left and right sides, forming two sets of clearly spaced pins, completing the first split.

[0089] The second gripper 142 of the second transfer gripper unit 14 moves along the second moving assembly 141 to pick up the split magnetic ring inductor from the first branching unit. The second gripper transfers it to the chamfering unit 15 and places it on the chamfering fixture 152. The V-shaped parts 153 move towards each other, clamping the pin or copper pillar body from both sides to achieve adaptive positioning. The pointed parts 154 that cooperate with the V-shaped parts work together to provide a precise machining reference for the pin ends, which are then chamfered to make the pin ends regular in shape.

[0090] The second transfer gripper unit 14 then transfers the chamfered magnetic ring inductor to the soldering unit 16. The magnetic ring inductor is placed on the carrier 162, where a separator plate 163 separates and positions the two sets of leads. The leads are soldered in fixed positions to enhance their solderability or meet specific process requirements.

[0091] The third gripper 172 of the third transfer gripper unit 17 moves along the third moving assembly 171 to pick up the magnetic ring inductor from the soldering unit. The third gripper transfers it to the processing position of the second splitting unit 18. After the magnetic ring inductor is placed or positioned, the splitting module 182 moves into place on the second slide rail 181. The tapered block 186 in the middle of the splitting block 185 is inserted between the pins. The drive cylinders 183 on both sides of the splitting block actuate, pushing the pusher blocks 184 to move to both sides, using the guiding effect of the tapered blocks to further split or reshape the pins, ensuring that the pin spacing ultimately meets the strict installation size requirements.

[0092] Furthermore, referring to Figures 12 to 18 As shown, the magnetic ring inductor base mounting device 200 includes a base transport unit 2-11, a winding copper column transport unit 2-12, a transfer unit 2-13, an installation unit 2-14, and a conveying unit 2-15.

[0093] The base transport unit 2-11 includes a vibratory feeder 2-111, one end of which is provided with a transport track 2-112. The base 104 is located inside the vibratory feeder 2-111, and the base 104 is transported one by one through the vibratory feeder 2-111.

[0094] A support fixture 2-114 is provided on one side of the transport track 2-112. The support fixture 2-114 can move on the adjustment track 2-113 and adjust the installation position of the support fixture 2-114.

[0095] A first moving component 2-115 is mounted on top of the support fixture 2-114, and a first gripper component 2-116 is provided on the first moving component 2-115. The base 104 on the transport track 2-112 is gripped onto the support fixture 2-114 through the cooperation of the first moving component 2-115 and the first gripper component 2-116.

[0096] In this embodiment, the vibratory feeder 2-111 of the base transport unit 2-11 begins operation, orienting and arranging the internally stacked bases 104, and outputting them one by one to the transport track 2-112 connected to it. The transport track 2-112 transports the bases 104 to a predetermined picking position. The first moving component 2-115 located above it drives the first gripper component 2-116 to move to this position. After the first gripper component 2-116 grasps the base 104, the first moving component 2-115 transports it above the support fixture 2-114. The support fixture 2-114 can be positioned by adjusting the track 2-113 to ensure accurate reception and fixation of the bases 104.

[0097] The winding copper pillar transport unit 2-12 organizes and transports the winding copper pillar 102 and its leads 103 to the picking station. The transfer unit 2-13 picks up the winding copper pillar 102 from the picking station of the winding copper pillar transport unit 2-12 and transfers it to the working area of ​​the installation unit 2-14. The transfer unit 2-13 includes a second mounting frame 2-131, on which a second moving assembly 2-132 is mounted. A third gripper assembly 2-133 is provided on the second moving assembly 2-132. The third gripper assembly 2-133 is used to transfer the base 104 on the carrying fixture 2-114 to the installation unit 2-14.

[0098] The winding copper column transport unit 2-12 includes a first mounting frame 2-121, on which a rotating arm 2-122 capable of circumferential rotation is provided. A second gripper assembly 2-123 is provided at one end of the rotating arm 2-122, which transfers the winding copper column 102 transported from the external production line to the mounting unit 2-14.

[0099] Furthermore, the installation unit 2-14 includes a third moving component 2-141, on which a jig plate 2-142 is mounted, and an installation jig 2-143 is disposed above the jig plate 2-142.

[0100] The mounting fixture 2-143 is equipped with a first cylinder 2-144 and a second cylinder 2-145. The output shafts of the first cylinder 2-144 and the second cylinder 2-145 are each equipped with a clamping plate 2-146, and the opening and closing of the clamping plate 2-146 is controlled by the first cylinder 2-144 and the second cylinder 2-145.

[0101] The third gripper assembly 2-133 transfers the base 104 from the carrying fixture 2-114 to the mounting fixture 2-143. The clamping plate 2-146 is used to clamp both sides of the base 104. A tapered guide groove 2-147 is provided in the middle of the clamping plate 2-146. The second gripper assembly 2-123 transfers the wound copper pillar 102 transported from the external production line to the mounting fixture 2-143, and then aligns and presses it in place using the second gripper assembly 2-123. The tapered guide groove 2-147 guides the installation, ensuring that the pins 103 on the wound copper pillar 102 can be smoothly inserted into the base 104.

[0102] In this embodiment, the base transport unit 2-11 is responsible for the orientation, transport, and initial positioning of the base; the winding copper column transport unit 2-12 is responsible for gripping and transferring the winding copper column to the assembly station; the transfer unit 2-13 is responsible for transferring the positioned base from the support fixture to the installation fixture; the installation unit 2-14 realizes the precise alignment of the base and the winding copper column and the insertion of the pins; and the transport unit 2-15 is responsible for outputting the assembled product to the next process.

[0103] Specifically, the vibratory feeder 2-111 has a built-in orientation mechanism that ensures the base 104 is output in an orderly manner according to a preset posture. The transport track 2-112 receives the bases output by the vibratory feeder and transports them to the unloading station. The first moving component 2-115 drives the first gripper component 2-116 to grasp the bases and transfer them to the supporting fixture 2-114. The supporting fixture can be finely adjusted in position by adjusting the track 2-113 to ensure accurate positioning of the bases.

[0104] The rotating arm 2-122 rotates under the drive of the servo motor, which drives the second gripper assembly 2-123 to pick up the winding copper column 102 from the feeding position.

[0105] The wound copper post is transferred to the assembly position above the mounting unit, ready for pressing installation. The second moving component 2-132 drives the third gripper component 2-133 to grab the base on the support fixture and transfer it to the mounting fixture 2-143.

[0106] After the base is placed in the mounting fixture, the first cylinder 2-144 and the second cylinder 2-145 push the clamping plate 2-146 to clamp the base from both sides. The clamping plate has a tapered guide groove 2-147 in the middle, whose funnel structure guides the pin 103 to automatically align during insertion. The winding copper post is pressed down by the second gripper assembly 2-123, and the pin is guided through the tapered guide groove into the corresponding insertion hole on the base, completing the assembly.

[0107] After installation, the wound copper column 102 is transported outward through the conveying unit 2-15 to enter the next process.

[0108] Further, refer to Figures 19 to 26 As shown, the magnetic ring inductor partition mounting equipment 300 includes a transfer gripper unit 3-11, a multi-station turntable unit 3-12, a limiting unit 3-13, a positioning unit 3-14, a partition mounting unit 3-15, and a transport unit 3-16.

[0109] The transfer gripper unit 3-11 includes a first mounting frame 3-111, on which a first drive assembly 3-112 is mounted. The first drive assembly 3-112 is mounted with a first gripper assembly 3-113 and a second gripper assembly 3-114.

[0110] The multi-station turntable unit 3-12 includes a second mounting bracket 3-121, on which a drive motor 3-122 is mounted. The drive motor 3-122 drives the turntable 3-123 to rotate in the F1 direction via a bevel gear set. Four mounting stations 3-124 are arranged circumferentially and at equal intervals on the turntable 3-123.

[0111] In this embodiment, the magnetic ring inductor 10, which has been installed on the base 104 but not yet on the partition 107, is moved by the first gripper assembly 3-113 to the currently idle installation station 3-124 of the multi-station turntable unit 3-12, and the magnetic ring inductor 10 is placed in the station.

[0112] The drive motor 3-122 drives the turntable 3-123 to rotate 90 degrees in the direction of F1 through the bevel gear set, so as to send the newly loaded inductor from station 1 to station 2. At the same time, the inductors on other stations also enter the next process.

[0113] The limiting unit 3-13 includes a third mounting bracket 3-131, on which a first cylinder 3-132 and a second cylinder 3-133 are mounted. The first cylinder 3-132 and the second cylinder 3-133 are vertically arranged, located on the side of the mounting station 3-124 away from the center of the turntable 3-123, and at the top of the mounting station 3-124, respectively.

[0114] When the magnetic ring inductor 10 rotates to station 2, the limiting unit 3-13 starts to work, pressing or clamping the base 104 and the magnetic core frame 101 from above or the side, ensuring that the inductor is completely fixed in the horizontal and vertical directions, and making the slot 106 on the base precisely aligned with the position to be installed.

[0115] The positioning unit 3-14 includes a fourth mounting bracket 3-141, and a positioning element 3-142 is provided in the middle of the fourth mounting bracket 3-141. Further, the partition mounting unit 3-15 includes a vibratory feeder 3-151, and a mounting assembly 3-152 is provided at the outlet of the vibratory feeder 3-151. The mounting assembly 3-152 includes a first hysteresis cavity 3-153 and a second hysteresis cavity 3-154.

[0116] The first hysteresis cavity 3-153 can reciprocate along the F2 direction. In the initial state, the first hysteresis cavity 3-153 is aligned with the outlet of the vibratory feeder 3-151. After movement, the first hysteresis cavity 3-153 is aligned with the second hysteresis cavity 3-154. The second hysteresis cavity 3-154 is fixed and aligned with the installation position 3-124.

[0117] Furthermore, the partition mounting unit 3-15 also includes a push cylinder 3-155, and a push pin 3-156 is provided on the output shaft of the push cylinder 3-155. The push pin 3-156 is used to penetrate the second hysteresis cavity 3-154 and push the partition located therein into the slot.

[0118] During the installation of the partition, the positioning element 3-142 is located on top of the magnetic core frame 101 and restricts the magnetic core frame 101.

[0119] In this embodiment, the working process of the partition installation unit 3-15 can be divided into three stages: partition conveying, temporary storage and alignment, and precise pushing. The vibratory feeder 3-151 is equipped with a spiral track and an orientation mechanism inside, which arranges the randomly stacked partitions 107 one by one into a neat arrangement and outputs them in an orderly manner along the outlet direction. The outlet of the vibratory feeder is aligned with the inlet of the first hysteresis cavity 3-153 in the initial position to ensure that the partitions can slide smoothly into the first hysteresis cavity.

[0120] The first hysteresis cavity 3-153 serves as a temporary storage and transfer mechanism for the partition, and can reciprocate in the F2 direction. It has a guide groove inside that matches the shape of the partition, ensuring that the partition maintains a stable posture during movement.

[0121] The first hysteresis chamber 3-153 is aligned with the vibratory feeder outlet and receives a partition. The first hysteresis chamber is translated along the F2 direction and aligned with the inlet of the second hysteresis chamber 3-154. The partition slides into the second hysteresis chamber with the assistance of gravity or micro-vibration. The outlet of the second hysteresis chamber 3-154 is precisely aligned with the slot 106 of the base in the installation station 3-124 to ensure that the partition push path is consistent.

[0122] The cylinder 3-155 has a push pin 3-156 mounted on its output shaft. Once the partition is in the second hysteresis chamber 3-154 and the inductor is fixed by the positioning unit 3-14, the cylinder is activated. The push pin 3-156 moves axially along the second hysteresis chamber, smoothly pushing out the partition and precisely inserting it into the base slot 106. The shape of the push pin's front end matches the partition to prevent damage to the partition or slot structure during the pushing process.

[0123] Furthermore, the transport unit 3-16 includes a fifth mounting bracket 3-161, which is equipped with a slide rail 3-162, and a blocking cylinder 3-163 is provided on one side of the slide rail 3-162. The installed magnetic ring inductor is transferred to the slide rail 3-162 by the second gripper assembly 3-114 and enters the next process.

[0124] Example 2

[0125] Based on the above embodiments, this embodiment further proposes a manufacturing process for magnetic ring inductors, which specifically includes the following steps:

[0126] Step 1: Place multiple magnetic ring inductors 10 on the transport fixture 113. Drive the transport fixture 113 forward through the first drive motor 111 and the first lead screw structure 112 to transport the magnetic ring inductors 10 sequentially to the gripping station. The first gripper 122 of the first transfer gripper unit 12 grips the magnetic ring inductor 10 and places it on the branching fixture 133 of the first branching unit 13. The limiting gripper 134 clamps the winding copper pillar 102 part of the magnetic ring inductor 10 from the front and back direction to realize the positioning and fixation of the magnetic ring inductor 10. Insert the four pins 103 of the magnetic ring inductor 10 into the guide groove of the branching plate 135 and drive the branching plate 135 to move horizontally in the left and right direction. Use the guide groove to evenly separate the four pins 103 to both sides to complete the first branching.

[0127] The limiting claw 134 uses a cylinder to drive the clamping plate to clamp the winding copper pillar 102 from the front and rear, ensuring that the root of the pin 103 is fixed. The guide groove on the splitter plate 135 is in clearance fit with the pin 103. When the splitter plate 135 moves horizontally, the side wall of the guide groove pushes the middle of the pin 103, causing the pin 103 to elastically deform around the root, thereby separating the pins and providing a suitable pin spacing for subsequent processes.

[0128] Step 2: The second gripper 142 of the second transfer gripper unit 14 picks up the magnetic ring inductor 10 that has completed the first wire splitting and transfers it to the chamfering unit 15; the magnetic ring inductor 10 is placed on the chamfering fixture 152, and the V-shaped parts 153 on both sides move towards each other to clamp the pin 103 or the winding copper pillar 102 body, and the pointed part 154 cooperates to provide a processing reference; the end of the pin 103 is chamfered to make the end of the pin 103 regular in shape to meet the subsequent installation requirements.

[0129] The V-groove of the V-shaped part 153 can accommodate pins 103 of different diameters and automatically positions the pins 103 at the center of the fixture when clamped. The cooperation between the pointed part 154 and the V-shaped part 153 ensures that the height of the pins 103 relative to the chamfering tool is consistent, ensuring uniform chamfering size and avoiding displacement during processing.

[0130] Step 3: The second transfer gripper unit 14 transfers the chamfered magnetic ring inductor 10 to the soldering unit 16; the magnetic ring inductor 10 is placed on the carrier 162, and the two sets of pins 103 that have been separated are separated and positioned by the partition plate 163; the pins 103 are soldered at the predetermined station to enhance the solderability of the pins 103 or to meet specific process requirements.

[0131] The separator 163 is inserted between the two sets of pins 103 to prevent the pins 103 from sticking or shifting during the soldering process and to ensure accurate soldering position. The soldering unit 16 usually adopts wave soldering or dip soldering to make the surface of the pins 103 uniformly covered with a tin layer.

[0132] Step 4: The third gripper 172 of the third transfer gripper unit 17 picks up the soldered magnetic ring inductor 10 and transfers it to the second branching unit 18; the branching module 182 moves into place and the conical block 186 is inserted between the pins 103; the drive cylinder 183 pushes the push block 184 to move to both sides, and the pins 103 are secondary branched or shaped by the guiding action of the conical block 186 to ensure that the spacing of the pins 103 finally meets the strict installation size requirements.

[0133] The tip of the conical block 186 gradually inserts into the gap between the pins 103. As the pusher block 184 moves outward, the inclined surface of the conical block 186 converts the pushing force into a lateral spreading force on the pins 103, causing the pins 103 to further separate and maintain a precise spacing, correcting any deviations that may have occurred in the previous process.

[0134] Step 5: The vibratory feeder 2-111 of the base transport unit 2-11 orients the bases 104 and outputs them one by one to the transport track 2-112; the first moving component 2-115 drives the first gripper component 2-116 to grab the bases 104 and place them on the support fixture 2-114; the position of the support fixture 2-114 is adjusted by adjusting the track 2-113 to ensure that the bases 104 are accurately positioned and ready for subsequent assembly.

[0135] The vibratory plate 2-111 uses centrifugal force and track shape to arrange the base 104 in a uniform posture; the adjustment function of the bearing fixture 2-114 can compensate for the positional error of the previous process and ensure that the mounting holes of the base 104 are aligned with the subsequent pins 103.

[0136] Step 6: The rotating arm 2-122 of the winding copper column transport unit 2-12 drives the second gripper assembly 2-123 to grab the winding copper column 102 from the feeding position; the winding copper column 102 is transferred to the assembly position above the installation unit 2-14, ready for pressing and installation.

[0137] The rotating arm 2-122 can achieve rapid and precise positioning, transferring the winding copper column 102 from the output end of the previous process to the assembly station, ensuring that the assembly rhythm with the base 104 is matched.

[0138] Step 7: The third gripper assembly 2-133 of the transfer unit 2-13 grips the base 104 on the carrier fixture 2-114 and transfers it to the mounting fixture 2-143 of the mounting unit 2-14; the first cylinder 2-144 and the second cylinder 2-145 push the clamping plate 2-146 to clamp the base 104 from both sides; the second gripper assembly 2-123 presses down the winding copper pillar 102, and the pin 103 is guided by the tapered guide groove 2-147 in the middle of the clamping plate 2-146, automatically aligns and inserts into the corresponding insertion hole of the base 104, completing the assembly of the base 104 and the winding copper pillar 102; the assembled magnetic ring inductor 10 is output to the next process through the conveying unit 2-15.

[0139] The tapered guide groove 2-147 is funnel-shaped, and its inclined surface can guide the pin 103 to smoothly enter the base socket even if there is a slight offset, so as to achieve flexible introduction; the clamping plate 2-146 clamps the base 104 from both sides to prevent the base 104 from shifting during assembly.

[0140] Step 8: The magnetic ring inductor 10 with the base 104 installed but without the partition 107 installed is placed into the installation station 3-124 of the multi-station turntable unit 3-12 via the first gripper assembly 3-113 of the transfer gripper unit 3-11; the drive motor 3-122 drives the turntable 3-123 to rotate, sending the magnetic ring inductor 10 to the partition installation station; the first cylinder 3-132 and the second cylinder 3-133 of the limiting unit 3-13 press the base 104 and the magnetic core frame 101 of the magnetic ring inductor 10 from above or the side, ensuring that it is in a horizontal position. The positions in the directional and height directions are completely fixed, and the slots 106 on the base 104 are precisely aligned with the installation position; the vibratory plate 3-151 of the partition mounting unit 3-15 arranges the partitions 107 and outputs them to the first hysteresis cavity 3-153. The first hysteresis cavity 3-153 moves to make the partitions 107 slide into the second hysteresis cavity 3-154; the push cylinder 3-155 drives the ejector pin 3-156 to smoothly push the partitions 107 out of the second hysteresis cavity 3-154 and precisely insert them into the slots 106 on the base 104, completing the installation of the partitions 107.

[0141] The multi-station turntable 3-123 enables continuous multi-station parallel operation, improving efficiency; the staggered docking design of the first hysteresis cavity 3-153 and the second hysteresis cavity 3-154 realizes the temporary storage and directional transfer of the partition 107, ensuring that the partition 107 enters the pushing station in the correct posture; the front end shape of the ejector pin 3-156 matches the partition 107, ensuring a smooth pushing process and avoiding damage to the partition 107 or the slot 106.

[0142] Step 9: Positioning unit 3-14 releases the restriction on magnetic ring inductor 10; second gripper assembly 3-114 removes the installed magnetic ring inductor 10 from the installation station 3-124 and transfers it to the slide rail 3-162 of transport unit 3-16; blocking cylinder 3-163 controls the product flow on slide rail 3-162, so that the assembled magnetic ring inductor 10 enters the next process.

[0143] The blocking cylinder 3-163 intermittently releases products to prevent them from accumulating on the slide rail 3-162, ensuring continuous and stable operation of subsequent processes.

[0144] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automated assembly line for magnetic ring inductors, characterized in that, include: Transport unit (11) for transporting magnetic ring inductor (10); The first branching unit (13) includes a limiting claw (134) and a horizontally movable branching plate (135). The limiting claw (134) is used to clamp the winding copper pillar (102) of the magnetic ring inductor (10), and the branching plate (135) is used to separate the four pins (103) of the magnetic ring inductor (10) to both sides. A chamfering unit (15) is used to chamfer the ends of the pins (103); Soldering unit (16) is used to solder the pins (103); The second branching unit (18) is used to perform secondary branching or reshaping of the pin (103); It also includes a magnetic ring inductor base mounting device (200), the base mounting device (200) comprising: Base transport unit (2-11) for transporting base (104); The winding copper column transport unit (2-12) is used to transport the winding copper column (102). The mounting unit (2-14) includes a clamping plate (2-146) and a tapered guide groove (2-147) disposed in the middle of the clamping plate (2-146) for guiding the pin (103) into the socket of the base (104); It also includes a magnetic ring inductor partition mounting device (300), the partition mounting device (300) comprising: The multi-station turntable unit (3-12) has multiple installation stations (3-124). The limiting unit (3-13) is used to fix the position of the magnetic ring inductor (10); The partition mounting unit (3-15) includes a vibratory plate (3-151), a first hysteresis chamber (3-153), a second hysteresis chamber (3-154), and a push cylinder (3-155) for inserting the partition (107) into the slot (106) of the base (104).

2. The automated assembly line for magnetic ring inductors according to claim 1, characterized in that, The first branch unit (13) further includes a branch fixture (133) and a first slide rail (131). The branch fixture (133) is slidably disposed on the first slide rail (131), and the limiting claw (134) is mounted on the branch fixture (133).

3. The automated assembly line for magnetic ring inductors according to claim 1, characterized in that, The chamfering unit (15) includes a chamfering fixture (152), a relatively movable V-shaped part (153), and a pointed part (154) that cooperates with the V-shaped part (153). The V-shaped part (153) is used to clamp the pin (103) or the winding copper post (102).

4. The automated assembly line for magnetic ring inductors according to claim 1, characterized in that, The soldering unit (16) includes a carrier (162) and a partition plate (163) disposed in the middle of the carrier (162), the partition plate (163) being used to separate two sets of pins (103).

5. The automated assembly line for magnetic ring inductors according to claim 1, characterized in that, The second splitting unit (18) includes a splitting module (182), which includes a conical block (186) and a drive cylinder (183). The drive cylinder (183) is connected to a pusher (184). The conical block (186) is used to insert between pins (103) and guide the pins to separate.

6. The automated assembly line for magnetic ring inductors according to claim 1, characterized in that, The mounting unit (2-14) also includes a first cylinder (2-144) and a second cylinder (2-145) for driving the clamping plate (2-146) to clamp the base (104).

7. The automated assembly line for magnetic ring inductors according to claim 1, characterized in that, The base transport unit (2-11) includes a vibratory plate (2-111), a transport track (2-112), and a movable support fixture (2-114), which is used to receive and position the base (104).

8. The automated assembly line for magnetic ring inductors according to claim 1, characterized in that, The first hysteresis chamber (3-153) is reciprocating and is used to transfer the partition (107) from the vibratory feeder outlet to the second hysteresis chamber (3-154), and the second hysteresis chamber (3-154) is aligned with the installation station (3-124).

9. A manufacturing process for magnetic ring inductors, comprising the automated assembly line for magnetic ring inductors as described in claim 1, characterized in that, The manufacturing process of the magnetic ring inductor includes: Step 1: Perform the first wire splitting on the pin (103) through the first wire splitting unit (13); Step 2: Chamfer the ends of the pins (103) using the chamfering unit (15); Step 3: Solder the pins (103) using the soldering unit (16); Step 4: Perform secondary splitting or reshaping of pin (103) through the second splitting unit (18).

10. The manufacturing process for magnetic ring inductors according to claim 9, characterized in that, Before Step 1, the magnetic ring inductor (10) is transported to the gripping station by the transport unit (11), and the magnetic ring inductor (10) is transferred to the first branching unit (13) by the first transfer gripper unit (12). After Step 4, there are also steps to insert the pin (103) into the base (104) and to insert the partition (107) into the slot (106) of the base (104).

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