Inductive double station winding device

Abstract

The application relates to the technical field of inductor manufacturing equipment, in particular to a double-station winding device for inductors, which comprises a storage container and a lifting platform in the storage container. Fixed frames are symmetrically arranged on the lifting platform, and a magnetic core fixing assembly and a wire end fixing assembly are respectively arranged on the fixed frames. Two center-symmetric circular-arc-shaped sliding grooves are arranged on the lifting platform, sliding blocks in the circular-arc-shaped sliding grooves are connected with winding rings through sliding rails. The winding rings are provided with coil sliding grooves, radial winding holes and axial magnetic core through holes. The sliding blocks are provided with a revolution driving assembly for driving the sliding blocks to move along the sliding grooves and a rotation driving assembly for driving the winding rings to rotate. The double-station symmetric layout and the combined motion of the revolution and rotation of the winding rings can synchronously and uniformly wind two groups of coils on one magnetic core, and the efficiency is high. Moreover, the device can work in a lubricating oil environment, can continuously lubricate the moving parts and can reduce the friction and wire abrasion in the winding process.

Description

Technical Field

[0001] This invention relates to the field of inductor manufacturing equipment technology, and more specifically to an inductor dual-station winding device. Background Technology

[0002] In the manufacturing of inductors, winding is one of the key processes, and its quality directly affects the electrical performance of the inductor. For inductor products that require two sets of coils to be wound on a single magnetic core, traditional winding processes usually employ single-station sequential operations or multiple machines, which result in low production efficiency, large equipment footprint, and difficulty in ensuring consistency between different coils.

[0003] In addition, conventional winding devices rely heavily on mechanical damping or manual experience to control wire tension during the winding process. This results in low control accuracy and poor stability, which can easily lead to the wire being wound too tightly, damaging the wire, or too loosely, causing the coil to become loose and affecting the product qualification rate.

[0004] Meanwhile, friction during the winding process can easily damage the insulation layer on the surface of the wire, and wear of moving parts can affect the accuracy and reliability of the equipment in long-term operation.

[0005] Therefore, how to achieve high efficiency, high consistency, and high quality in synchronously winding two sets of coils on a single magnetic core is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0006] In order to achieve high efficiency, high consistency and high quality in synchronously winding two sets of coils on a single magnetic core, this application provides an inductor dual-station winding device.

[0007] The inductor dual-station winding device provided in this application adopts the following technical solution: A dual-station inductor winding device includes a storage container filled with lubricating oil. A lifting platform is slidably connected inside the storage container, and a lifting drive assembly, pulsatingly connected to the lifting platform, is mounted on the storage container. Symmetrically arranged fixed frames are mounted on the lifting platform, and magnetic core fixing assemblies and wire end fixing assemblies are respectively mounted on the fixed frames. Two centrally symmetrical arc-shaped grooves are formed on the lifting platform around the center of the magnetic core fixing assemblies. Arc-shaped sliders are slidably connected inside each arc-shaped groove, and arc-shaped slide rails are fixedly connected to each arc-shaped slider. Winding rings are slidably connected inside each arc-shaped slide rail. Coil grooves are formed along the circumference of each winding ring, winding holes are formed along the radial direction of each winding ring, and obliquely arranged magnetic core through-holes are formed along the axial direction of each winding ring. A revolution drive assembly, pulsatingly connected to the lifting platform, and a rotation drive assembly, pulsatingly connected to the winding ring, are fixedly mounted on each arc-shaped slider.

[0008] By adopting the above technical solution, and utilizing the dual-station symmetrical layout combined with the combined motion of the winding ring's revolution around the magnetic core axis and its own rotation, two sets of coils can be wound simultaneously, uniformly, and tightly on a single magnetic core, resulting in high production efficiency. Furthermore, winding in a closed environment filled with lubricating oil provides continuous lubrication to the moving parts and significantly reduces friction and wear of the wire during the winding process.

[0009] Furthermore, a tension sensing component is installed inside the winding hole, and the tension sensing component is electrically connected to a control system. The control system is electrically connected to the revolution drive component and the rotation drive component.

[0010] By adopting the above technical solution, the tension sensing component can monitor the winding tension in real time and in situ. The control system dynamically adjusts the motion parameters of the revolution and rotation drive components based on the feedback signal, forming a closed-loop control to ensure constant winding tension. This effectively avoids wire damage or breakage due to excessive tension, as well as loose winding due to insufficient tension, significantly improving the consistency of winding quality and product qualification rate.

[0011] Furthermore, the lifting drive assembly includes a drive screw, the bottom end of which is rotatably connected to the inner bottom surface of the storage container. A top cover is fixedly installed on the top surface of the storage container, and a lifting hole is provided in the center of the top cover. A lifting drive motor is fixedly installed on the top cover, and the output shaft of the lifting drive motor is coaxially fixedly connected to the top of the drive screw. The lifting platform is installed below the top cover, and a spiral hole is provided on the lifting platform for threaded transmission connection with the drive screw.

[0012] By adopting the above technical solution, the screw drive mechanism provides the lifting platform with a smooth, precise, and self-locking linear drive, reliably raising and lowering the winding mechanism to the lubrication working position or the top operating position. The drive motor is located on the top cover, resulting in a compact structure, stable operation, and the screw is protected in the lubrication environment, extending its service life.

[0013] Furthermore, the magnetic core fixing assembly includes two coaxially symmetrically arranged telescopic members, which are respectively fixedly installed on the two symmetrically arranged fixing frames. The ends of the two telescopic members that are close to each other are telescopic ends, and each telescopic end of the telescopic member is fixedly installed with a clamping block that matches the shape of the outer ring of the magnetic core.

[0014] By adopting the above technical solution, and using two symmetrical telescopic components to drive the elastic clamping blocks, automatic centering and stable clamping can be achieved from both ends of the magnetic core. The elastic clamping blocks can adapt to magnetic cores of different sizes, providing uniform clamping force, which can not only firmly fix the core but also effectively avoid damage to the surface of the magnetic core caused by rigid clamping.

[0015] Furthermore, the wire end fixing assembly includes a wire end positioning hole on the fixing frame, a threaded hole on the fixing frame that communicates with the wire end positioning hole, a locking screw threadedly connected inside the threaded hole, and a knob fixedly connected to the outer end of the locking screw.

[0016] By adopting the above technical solution, the wire end fixing component structure is extremely simple and compact. By rotating the knob to drive the locking screw to clamp the wire, quick and reliable fixing and releasing of the wire end can be achieved. The operation is convenient, the clamping force is adjustable, and a stable starting tension point is provided for winding.

[0017] Furthermore, the revolution drive assembly includes a first waterproof motor, which is fixedly mounted on the arc-shaped slider. A first drive gear is fixedly mounted on the output shaft of the first waterproof motor. An arc-shaped rack is fixedly mounted on the lifting platform corresponding to the first drive gear. The first drive gear meshes with the arc-shaped rack, and the center of the arc-shaped rack coincides with the center of the arc-shaped groove.

[0018] By adopting the above technical solution, the revolution drive uses a gear meshing with a fixed circular arc rack to directly and accurately convert the rotational motion of the motor into the circular arc motion of the winding around the magnetic core axis. The transmission path is clear, the speed control is precise, and the center of the circular arc rack coincides with the center of the groove, ensuring the accuracy of the revolution trajectory, which is the key to achieving uniform winding.

[0019] Furthermore, the revolution drive assembly includes a first waterproof motor, which is fixedly mounted on the arc-shaped slider. A first drive gear is fixedly mounted on the output shaft of the first waterproof motor. An arc-shaped tooth groove is provided on the lifting platform corresponding to the first drive gear. The first drive gear meshes with the arc-shaped tooth groove, and the center of the arc-shaped tooth groove coincides with the center of the arc-shaped slide groove.

[0020] By adopting the above technical solution, the independent arc-shaped rack is optimized into an arc-shaped toothed groove directly machined on the lifting platform body. This design eliminates component assembly errors, making the structure more compact and the overall rigidity higher. The transmission path is more direct, the trajectory accuracy is entirely guaranteed by the platform's machining accuracy, and the toothed groove is easier to store lubricating oil, improving the smoothness and durability of the transmission.

[0021] Furthermore, the self-rotating drive assembly includes a second waterproof motor, which is fixedly mounted on the arc-shaped slider. A second drive gear is fixedly mounted on the output shaft of the second waterproof motor. The end face of the winding ring is provided with an annular tooth groove corresponding to the second drive gear. A first clearance opening is provided on the arc-shaped slide rail. The second drive gear passes through the first clearance opening and meshes with the annular tooth groove.

[0022] By adopting the above technical solution, the rotation drive uses an internal meshing method between the motor gear and the annular tooth groove on the end face of the winding ring. This design makes full use of the space on the end face of the winding ring, resulting in an extremely compact transmission structure, which is particularly suitable for arrangement in space-constrained sliding mechanisms. It enables unrestricted continuous rotation of the winding ring, with a short transmission chain, fast response, and high control precision.

[0023] Furthermore, the arc-shaped slide rail is provided with several second clearance openings equidistantly distributed along its length direction. Each of the arc-shaped slide rails is rotatably connected to an auxiliary gear corresponding to the second clearance opening. The auxiliary gear passes through the second clearance opening and meshes with the annular tooth groove.

[0024] By adopting the above technical solution, multiple auxiliary gears that mesh with the tooth grooves of the winding ring are set on the slide rail, providing multi-point auxiliary support for the winding ring along its motion trajectory. This greatly enhances the rigidity and operational stability of the winding ring during high-speed rotation, effectively prevents swaying and vibration, reduces the load on the second drive gear, and improves system reliability.

[0025] Furthermore, the tension sensing component includes two sets of symmetrically arranged pressure sensors, which are symmetrically installed inside the winding hole. The ends of the pressure sensors that are close to each other are the detection ends. A roller bracket is fixedly installed on the detection end of the pressure sensor, and a roller is rotatably connected to the roller bracket.

[0026] By adopting the above technical solution, the tension sensor uses a symmetrical double-roller and pressure sensor structure. The wire passes between the two rollers, converting sliding friction into rolling friction, which significantly reduces wear on the wire during the measurement process. The sensor directly detects the pressure of the wire on the rollers, providing direct measurement and rapid feedback. The symmetrical layout can adapt to different winding directions, improving the accuracy and reliability of tension measurement.

[0027] Beneficial effects achieved: This application discloses an inductor dual-station winding device that, through a symmetrical dual-station design and the combined motion of the winding ring's revolution and rotation, achieves synchronous, efficient, and high-quality winding of two sets of coils on a single magnetic core. An integrated tension closed-loop control system ensures stable winding tension and guarantees coil consistency. Fully lubricated operation protects the wire and moving parts. All components, such as the magnetic core fixing, wire end fixing, lifting, and drive mechanisms, are rationally designed, easy to operate, and stable and reliable. The overall device boasts a high degree of automation, high winding accuracy, significantly improved production efficiency, and is suitable for long-term continuous and stable operation. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of one embodiment of this application.

[0029] Figure 2 This is a structural exploded view of one embodiment of this application.

[0030] Figure 3 This is a schematic diagram of the internal structure of one embodiment of this application.

[0031] Figure 4 This is an exploded view of the structure of the magnetic core fixing assembly and the wire end fixing assembly in one embodiment of this application.

[0032] Figure 5 This is a partial structural schematic diagram of the revolution drive component in one embodiment of this application.

[0033] Figure 6 This is a partial structural diagram of a self-rotating drive component in one embodiment of this application.

[0034] Figure 7 This is an exploded view of the structure of a self-rotating drive component in one embodiment of this application.

[0035] Figure 8 This is a schematic diagram of the internal structure of a tension sensing component in one embodiment of this application.

[0036] Explanation of reference numerals in the attached drawings: 100, storage container; 101, lifting platform; 102, fixing frame; 103, arc-shaped slide groove; 104, arc-shaped slider; 105, arc-shaped slide rail; 106, winding ring; 107, coil slide groove; 108, winding hole; 109, magnetic core through hole; 110, oil passage hole; 200, lifting drive assembly; 201, drive screw; 202, top cover; 203, lifting hole; 204, lifting drive motor; 205, spiral hole; 300, magnetic core fixing assembly; 301, telescopic component; 302, clamping block; 303, locking seat; 304, mounting groove; 400, wire end fixing assembly. Components; 401, Wire end positioning hole; 402, Threaded hole; 403, Locking screw; 404, Knob; 500, Revolution drive assembly; 501, First waterproof motor; 502, First drive gear; 503, Arc-shaped rack; 504, Arc-shaped tooth groove; 600, Rotation drive assembly; 601, Second waterproof motor; 602, Second drive gear; 603, Circular tooth groove; 604, First clearance opening; 605, Second clearance opening; 606, Auxiliary gear; 700, Tension sensing assembly; 701, Pressure sensor; 702, Roller bracket; 703, Roller; 800, Wire; 900, Magnetic core. Detailed Implementation

[0037] The following combination Figures 1-8 This application will be described in further detail.

[0038] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, 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, and therefore should not be construed as a limitation of the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0039] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0040] This application discloses an inductor dual-station winding device.

[0041] Please refer to the above as well. Figures 1 to 8 In one embodiment of this application, an inductor dual-station winding device includes a storage container 100 filled with lubricating oil, a lifting platform 101 slidably connected inside the storage container 100, and a lifting drive assembly 200 connected to the lifting platform 101 on the storage container 100. A symmetrically arranged fixing frame 102 is installed on the lifting platform 101, and a magnetic core fixing assembly 300 and a wire end fixing assembly 400 are respectively installed on the fixing frame 102. The magnetic core fixing assembly 300 is used to fix the magnetic core 900; the wire end fixing assembly 400 is used to fix the end of the wire 800. Two centrally symmetrical arc-shaped sections are formed on the lifting platform 101 around the center of the magnetic core fixing assembly 300. The slide groove 103 and the arc-shaped slide groove 103 are all slidably connected to the arc-shaped sliders 104. The arc-shaped slide rails 105 are all fixedly connected to the arc-shaped sliders 104. The winding rings 106 are all slidably connected to the arc-shaped slide rails 105. The winding rings 106 have coil grooves 107 along their circumference, winding holes 108 along their radial direction, and obliquely arranged magnetic core through holes 109 along their axial direction. The lifting platform 101 has several oil passage holes 110 arranged in a ring. The arc-shaped sliders 104 are all fixedly installed with a revolution drive assembly 500 that is connected to the lifting platform 101 and a rotation drive assembly 600 that is connected to the winding rings 106.

[0042] During operation, the height of the lifting platform 101 is first adjusted using the lifting drive assembly 200, raising the lifting platform 101 to the top of the storage container 100. Then, the magnetic core 900 is fixed on the magnetic core fixing assembly 300. Next, two winding rings 106 are inserted and fastened into the magnetic core 900 through the magnetic core through-hole 109. Then, the wire 800 is passed through the winding hole 108, and one end of the wire 800 is led out to the inside of the winding ring 106 and fixed on the wire end fixing assembly 400. Finally, the height of the lifting platform 101 is adjusted using the lifting drive assembly 200, lowering the lifting platform 101 into the inside of the storage container 100 for winding.

[0043] During the winding operation, the revolution drive assembly 500 drives the arc-shaped slider 104 to slide along the arc-shaped slide groove 103, causing the winding ring 106 to revolve around the magnetic core 900. At the same time, the rotation drive assembly 600 drives the winding ring 106 to rotate within the arc-shaped slide rail 105. Under the guidance of the coil slide groove 107, the wire 800 passing through the winding hole 108 will be evenly wound on the magnetic core 900.

[0044] This application achieves simultaneous winding of two sets of coils on the magnetic core through a dual-station symmetrical design, which greatly improves production efficiency; the combined motion of revolution and rotation ensures tight and uniform winding; and winding in lubricating oil not only provides continuous lubrication to the moving parts, but also prevents the wire 800 from jamming during the winding process, and reduces wear on the wire 800, which helps to ensure coil quality.

[0045] Please refer to the above as well. Figures 1 to 8 In one specific embodiment of this application, a tension sensing component 700 is installed inside the winding hole 108. The tension sensing component 700 is electrically connected to a control system, and the control system is electrically connected to the revolution drive component 500 and the rotation drive component 600.

[0046] During operation, the tension sensing component 700 monitors the tension value of the wire 800 passing through the winding hole 108 in real time and feeds the data back to the control system. The control system compares the real-time tension value with the preset tension range and performs dynamic, closed-loop control of the winding tension by adjusting the driving speed of the revolution drive component 500 and / or the driving speed of the rotation drive component 600, ensuring that the tension of the wire 800 remains stable during the winding operation.

[0047] This embodiment, by introducing a tension sensing component 700 and a control system, realizes real-time monitoring and automatic adjustment of winding tension, effectively avoiding wire stretching damage or breakage caused by excessive tension, as well as loose and uneven winding caused by insufficient tension, significantly improving the consistency of coil winding and product quality.

[0048] The automatic control system can adapt to wires of different specifications, enhancing the versatility and intelligence of the device. Combined with the existing lubrication system, winding under stable tension further reduces frictional damage to the wire surface, comprehensively ensuring the electrical performance and reliability of the coil.

[0049] Please refer to the above as well. Figures 1 to 8 In one specific embodiment of this application, the lifting drive assembly 200 includes two sets of symmetrically arranged drive screws 201. The two sets of drive screws 201 are vertically arranged inside the storage container 100 near its side wall. The bottom end of the drive screw 201 is rotatably connected to the inner bottom surface of the storage container 100. A top cover 202 is fixedly installed on the top surface of the storage container 100. A lifting hole 203 is opened in the center of the top cover 202. Lifting drive motors 204 are fixedly installed on the top cover 202 corresponding to the two sets of drive screws 201. The output shaft of the lifting drive motor 204 is coaxially fixedly connected to the top of the corresponding drive screw 201. A lifting platform 101 is installed below the top cover 202. A spiral hole 205 is opened on the lifting platform 101 for threaded transmission connection with the drive screw 201.

[0050] During operation, when the lifting platform 101 needs to be raised or lowered, the lifting drive motor 204 is started synchronously to drive the two drive screws 201 to rotate synchronously. Through the threaded transmission of the drive screws 201 and the spiral hole 205, the lifting platform 101 can be raised and lowered smoothly.

[0051] This embodiment provides a balanced and stable bidirectional linear drive by connecting two sets of symmetrically arranged drive screws 201 to the lifting platform 101. This effectively prevents platform skewing and shaking during lifting, providing a benchmark guarantee for high-precision winding. The screw drive has a self-locking characteristic, reliably maintaining the stability of the lifting platform at any height. This structure integrates the drive components onto the top cover 202 of the storage container 100, resulting in a compact structure that saves space. It also strictly limits the lifting path of the lifting platform 101, ensuring smooth operation and low noise. Combined with the lubricating oil inside the storage container 100, the moving parts such as the screws receive good lubrication and protection during operation, improving the reliability and service life of the entire lifting drive system.

[0052] It is understood that in other specific embodiments of this application, the lifting drive assembly 200 may also be configured as one drive screw 201 or multiple drive screws 201, which may also drive the lifting platform 101 to lift.

[0053] Please refer to the above as well. Figures 1 to 8In one specific embodiment of this application, the magnetic core fixing assembly 300 includes two coaxially symmetrically arranged telescopic members 301. The telescopic members 301 are respectively fixedly installed on two symmetrically arranged fixing frames 102. The ends of the two telescopic members 301 that are close to each other are telescopic ends. Each telescopic end of the telescopic member 301 is fixedly installed with a clamping block 302 that matches the shape of the outer ring of the magnetic core 900. The clamping block 302 is made of a material with a certain elasticity, such as rubber. A locking seat 303 is detachably installed on the top of the fixing frame 102 corresponding to the telescopic member 301. The locking seat 303 and the fixing frame 102 are fitted with an installation groove 304 corresponding to the telescopic member 301.

[0054] During operation, the two telescopic components 301 first retract the clamping blocks 302 at their front ends. The operator places the magnetic core 900 between the two clamping blocks 302, then controls the two telescopic components 301 to extend synchronously, using the elastic clamping blocks 302 to clamp the magnetic core 900 from both ends. Due to the elastic material properties of the clamping blocks 302, they can adaptively fit the outer ring of the magnetic core 900 of different sizes or with slight manufacturing tolerances, providing uniform clamping force. After the winding operation is completed, the telescopic components 301 are retracted, and the wound magnetic core assembly can be removed.

[0055] This embodiment uses two symmetrical telescopic members 301 to drive the elastic clamping block 302 for dual-point centering and fixing, ensuring that the magnetic core 900 is stably and accurately positioned on the winding axis, providing a foundation for high-precision winding. The elastic clamping block 302 can effectively clamp while avoiding surface damage or stress concentration of the magnetic core that may be caused by rigid clamping. This component has a simple structure, is easy to operate, has high clamping and release efficiency, and is easy to maintain and replace parts.

[0056] Please refer to the above as well. Figures 1 to 8 In some specific embodiments of this application, the telescopic member 301 can be configured as an electric telescopic rod, a hydraulic telescopic cylinder, a pneumatic telescopic rod, or other device or equipment capable of synchronous telescopic movement.

[0057] Please refer to the above as well. Figures 1 to 8 In one specific embodiment of this application, the wire end fixing assembly 400 includes a wire end positioning hole 401 on a fixing frame 102, a threaded hole 402 communicating with the wire end positioning hole 401 on the fixing frame 102, a locking screw 403 threadedly connected inside the threaded hole 402, and a knob 404 fixedly connected to the outer end of the locking screw 403.

[0058] During the operation, the end of the wire 800 is first inserted into the wire end positioning hole 401. Then, the operator rotates the knob 404, driving the locking screw 403 to screw into the wire end positioning hole 401. The end of the locking screw 403 presses against and secures the wire 800 passing through the wire end positioning hole 401, thereby firmly locking its end onto the fixing frame 102 and providing a stable starting tension point for winding. After the winding operation is completed, the knob 404 is rotated in the opposite direction to disengage the locking screw 403, allowing the wire end to be released.

[0059] This embodiment features a simple and compact structure, making operation more convenient. Quick locking and releasing of the wire end can be achieved simply by rotating the knob, significantly improving clamping efficiency. The threaded locking method provides a stable and adjustable clamping force, ensuring that the wire's starting end will not slip or loosen during winding, guaranteeing a neat starting section and stable tension. The entire assembly consists of only a few parts, resulting in low manufacturing costs, high reliability, and easy maintenance.

[0060] Please refer to the above as well. Figures 1 to 8 In one specific embodiment of this application, the revolution drive assembly 500 includes a first waterproof motor 501, which is fixedly mounted on the arc-shaped slider 104. A first drive gear 502 is fixedly mounted on the output shaft of the first waterproof motor 501. An arc-shaped rack 503 is fixedly mounted on the lifting platform 101 corresponding to the first drive gear 502. The first drive gear 502 meshes with the arc-shaped rack 503, and the center of the arc-shaped rack 503 coincides with the center of the arc-shaped groove 103.

[0061] During operation, when the winding ring 106 needs to revolve around the magnetic core 900, the control system activates the first waterproof motor 501. The output shaft of the first waterproof motor 501 drives the first drive gear 502 to rotate. Since the first drive gear 502 meshes with the arc-shaped rack 503 fixedly mounted on the lifting platform 101, and the center of the arc-shaped rack 503 coincides with the center of the arc-shaped groove 103, the meshing transmission between the gear and the rack is converted into the precise and smooth arc-shaped movement of the arc-shaped slider 104 along the arc-shaped groove 103, thereby driving the winding ring 106 fixed on it to revolve around the axis of the magnetic core 900.

[0062] This embodiment employs a gear and fixed circular arc rack meshing transmission method to achieve revolution drive. The transmission path is direct and efficient, with precise speed control and rapid response, meeting the high requirements of the winding process for revolution speed stability. The configuration of the first waterproof motor 501 ensures long-term reliable operation of the drive core in a lubricated working environment. The entire drive mechanism directly converts rotary motion into the required circular motion. Its compact structure and motion trajectory are guaranteed by the mechanical structure itself, resulting in high precision and rigidity. This ensures that the center of the revolution trajectory of the winding ring 106 remains aligned with the magnetic core axis, a crucial foundation for achieving uniform and tight winding of the coil on the magnetic core.

[0063] Please refer to the above as well. Figures 1 to 8 In another specific embodiment of this application, the revolution drive assembly 500 includes a first waterproof motor 501, which is fixedly mounted on the arc-shaped slider 104. A first drive gear 502 is fixedly mounted on the output shaft of the first waterproof motor 501. An arc-shaped toothed groove 504 is provided on the lifting platform 101 corresponding to the first drive gear 502. The first drive gear 502 meshes with the arc-shaped toothed groove 504, and the center of the arc-shaped toothed groove 504 coincides with the center of the arc-shaped slide groove 103.

[0064] During operation, when the winding ring 106 needs to revolve around the magnetic core 900, the control system activates the first waterproof motor 501. The output shaft of the first waterproof motor 501 drives the first drive gear 502 to rotate. Since the first drive gear 502 meshes with the arc-shaped toothed groove 504 directly formed on the body of the lifting platform 101, and the center of the arc-shaped toothed groove 504 coincides with the center of the arc-shaped slide groove 103, the meshing transmission between the gear and the toothed groove is transformed into the precise and smooth arc-shaped movement of the arc-shaped slider 104 along the arc-shaped slide groove 103, thereby driving the winding ring 106 to revolve.

[0065] This embodiment optimizes the transmission rack structure into an arc-shaped toothed groove 504 directly machined on the lifting platform 101, eliminating the need for a separate rack component. This results in a more compact and integrated overall structure, reducing assembly steps and improving structural rigidity and integrity. This design eliminates potential cumulative errors from rack installation, ensuring that the alignment accuracy between the center of the orbital motion trajectory and the magnetic core axis is entirely guaranteed by the platform's machining precision. This leads to a more direct transmission path and more accurate and reliable positioning. Simultaneously, the toothed groove structure facilitates lubricant storage and coverage of the meshing area, providing continuous and effective lubrication and protection during long-term operation, further enhancing the stability, durability, and reliability of the transmission system under lubricated operating conditions.

[0066] Please refer to the above as well. Figures 1 to 8In one specific embodiment of this application, the self-rotating drive assembly 600 includes a second waterproof motor 601, which is fixedly mounted on the arc-shaped slider 104. A second drive gear 602 is fixedly mounted on the output shaft of the second waterproof motor 601. The end face of the winding ring 106 is provided with an annular tooth groove 603 corresponding to the second drive gear 602. A first clearance opening 604 is provided on the arc-shaped slide rail 105. The second drive gear 602 passes through the first clearance opening 604 and meshes with the annular tooth groove 603.

[0067] During operation, when the winding ring 106 needs to rotate around its own axis, the control system activates the second waterproof motor 601. The output shaft of the second waterproof motor 601 drives the second drive gear 602 to rotate. The second drive gear 602 passes through the first clearance opening 604 on the arc-shaped slide rail 105 and meshes with the annular toothed groove 603 on the end face of the winding ring 106. Through the internal meshing transmission between the gear and the annular toothed groove, the rotation of the second drive gear 602 is converted into a precise and continuous rotational motion of the winding ring 106 around its own axis inside the arc-shaped slide rail 105.

[0068] This embodiment employs a transmission method where the annular toothed groove 603, built into the end face of the winding ring, meshes with the second drive gear 602. This results in an extremely compact structure that fully utilizes the end face space of the winding ring, achieving tight integration of the drive assembly and the actuator. It is highly suitable for placement in space-constrained slide rail mechanisms. The annular toothed groove design allows the winding ring to rotate continuously without angular limitations, meeting the needs of winding with any number of turns. The second waterproof motor 601 ensures the long-term reliability of the drive source under lubricated working conditions. This direct drive method features a short transmission chain, no intermediate links, fast response speed, and high control precision, enabling precise coordination with revolutionary motion to achieve complex composite winding trajectories. Simultaneously, the meshing transmission between the gear and the toothed groove has good rigidity and small backlash, effectively ensuring the accuracy of the winding ring's rotation angle, thereby ensuring that the arrangement of each coil turn is uniform and compact, ultimately guaranteeing the high quality and consistency of the coil product.

[0069] Please refer to the above as well. Figures 1 to 8 In one specific embodiment of this application, both the first waterproof motor 501 and the second waterproof motor 601 are electrically connected to the control system, which is a PLC controller.

[0070] During operation, when the winding operation begins, the PLC controller sends coordinated control commands to the first waterproof motor 501 and the second waterproof motor 601 according to a preset program. The PLC controller precisely controls the start, stop, speed, and direction of the first waterproof motor 501 to drive the winding ring 106 in revolution; simultaneously, it precisely controls the corresponding parameters of the second waterproof motor 601 to drive the winding ring 106 in rotation. The PLC controller ensures that the movements of the two motors are strictly synchronized and matched to form the required composite winding trajectory. In addition, the PLC controller receives tension feedback signals from the tension sensing component 700 in real time and dynamically adjusts the operating parameters of the two motors through the built-in control algorithm to achieve closed-loop automatic control of the winding tension, ensuring that the tension remains stable within the set range. The PLC controller can also store winding process parameters for various product specifications, enabling rapid switching between different products and automated production.

[0071] This implementation uses a PLC controller as the core control system, achieving precise and coordinated control of the revolution and rotation drives, as well as closed-loop automatic adjustment of winding tension, significantly improving the automation, intelligence, and precision of the entire winding process. This ensures high consistency, repeatability, and high yield in the winding operation. The tension closed-loop control effectively protects the wire and improves the electrical performance and reliability of the coil. Parametric programming makes the equipment highly flexible, quickly adapting to the production needs of multiple varieties and small batches. The system operates stably and reliably, reducing manual intervention and reliance on operational skills, significantly improving production efficiency and product quality stability.

[0072] Please refer to the above as well. Figures 1 to 8 In one specific embodiment of this application, a plurality of second clearance openings 605 are provided on the arc-shaped slide rail 105, which are equidistantly distributed along its length direction. An auxiliary gear 606 is rotatably connected to each of the second clearance openings 605 on the arc-shaped slide rail 105. The auxiliary gear 606 passes through the second clearance opening 605 and meshes with the annular tooth groove 603.

[0073] During operation, when the second waterproof motor 601 drives the winding ring 106 to rotate, the annular toothed groove 603 on the end face of the winding ring 106 will sequentially mesh with each of the auxiliary gears 606, causing it to rotate passively. These equidistantly distributed auxiliary gears 606 and the annular toothed groove 603 maintain meshing with each other at multiple positions simultaneously, jointly bearing the radial force and possible torsional torque generated by the winding ring 106 during rotation, providing multi-point auxiliary support and guidance for the movement of the winding ring 106 within the arc-shaped slide rail 105.

[0074] In this embodiment, multiple equidistant auxiliary gears 606 are added to the arc-shaped slide rail 105, forming a multi-tooth, continuous meshing support with the annular tooth groove 603 of the winding ring 106. This design distributes the load, which might otherwise be concentrated on the second drive gear 602, to multiple support points on the slide rail, greatly enhancing the rigidity and stability of the winding ring 106 during movement and effectively suppressing possible vibration, sway, or jamming. This ensures that the rotation axis of the winding ring 106 maintains extremely high positional accuracy and operational smoothness even at high speeds, high loads, or during variable-speed rotation, thereby directly improving the uniformity and consistency of the winding. At the same time, multi-point support reduces the load on the second drive gear 602, reduces wear, and improves the reliability and lifespan of the entire rotation drive system under long-term continuous operation.

[0075] Please refer to the above as well. Figures 1 to 8 In one specific embodiment of this application, the tension sensing assembly 700 includes two sets of symmetrically arranged pressure sensors 701. The pressure sensors 701 are symmetrically installed inside the winding hole 108. The ends of the pressure sensors 701 that are close to each other are the detection ends. A roller bracket 702 is fixedly installed on the detection end of the pressure sensor 701. A roller 703 is rotatably connected to the roller bracket 702. A limiting ring groove is opened on the circumference of the roller 703 corresponding to the wire 800.

[0076] During operation, when winding, the wire 800 passes through the winding hole 108 and is embedded between the limiting annular grooves of the two rollers 703. The movement of the wire 800 causes the rollers 703 to rotate, thus converting sliding friction into rolling friction. The tension of the wire 800 causes it to exert radial pressure on one of the two symmetrically arranged rollers 703, and this pressure is transmitted to the pressure sensor 701 through the roller bracket 702. The pressure sensor 701 detects this pressure value in real time and converts it into an electrical signal, which is then transmitted to the control system. Based on the received two symmetrical signals, the control system can more accurately calculate and feedback the real-time tension value of the wire 800 as it passes through the winding hole 108.

[0077] This embodiment achieves direct, in-situ, and non-contact measurement of winding tension by symmetrically arranging pressure sensors 701 with rollers 703 inside the winding hole 108 through which the wire passes. The measurement point is close to the winding action point, resulting in rapid and accurate feedback. The design of the rollers 703 converts the sliding friction between the wire 800 and the sensor detection end into rolling friction, reducing wear on the wire surface during measurement and avoiding tension measurement distortion caused by frictional resistance. The symmetrically arranged dual-sensor structure can offset the error caused by uneven force on one side, improving the accuracy and reliability of the measurement. The limiting ring groove effectively guides and restricts the path of the wire 800, ensuring that it always acts on the roller, improving the effectiveness of sensor detection. This provides a reliable sensing basis for real-time and accurate closed-loop tension control and is a key link in ensuring the quality of coil winding.

[0078] The implementation principle of the dual-station inductor winding device in this application is to achieve high-efficiency and high-quality coil winding through the synergy of a symmetrically arranged mechanical structure and intelligent control.

[0079] When the device is in operation, the magnetic core is first fixed in the center, and two winding loops are symmetrically placed on the magnetic core. The wire passes through the winding loops, and the starting end is fixed. The entire winding mechanism then descends into a sealed container filled with lubricating oil.

[0080] The core of the winding process is driving the winding ring to perform a compound motion: the revolution drive component drives the winding to move in an arc around the magnetic core axis, while the rotation drive component simultaneously drives the winding to rotate around its own axis. Through the precise combined motion of these two components, the wire is evenly and tightly wound onto the magnetic core. The dual-station symmetrical design allows two sets of coils to be wound simultaneously on both sides of the magnetic core, doubling the efficiency.

[0081] The precision and quality of the entire process are ensured by an intelligent closed-loop control system. Tension sensing components integrated into the winding holes monitor wire tension in real time and feed the signal back to the control system. The control system dynamically adjusts the motion parameters of the revolution and rotation motors to ensure constant tension, thereby preventing damage from excessive tightness or unevenness in the coil. Furthermore, operating in a lubricated environment continuously lubricates all moving parts, extending their lifespan, and reduces friction and wear on the wire during winding.

[0082] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An inductor dual-station winding device, characterized in that: The system includes a storage container (100) filled with lubricating oil, a lifting platform (101) slidably connected inside the storage container (100), and a lifting drive assembly (200) connected to the lifting platform (101) on the storage container (100). A symmetrically arranged fixing frame (102) is installed on the lifting platform (101), and a magnetic core fixing assembly (300) and a wire end fixing assembly (400) are respectively installed on the fixing frame (102). Two centrally symmetrical arc-shaped sliding grooves (103) are formed on the lifting platform (101) around the center of the magnetic core fixing assembly (300), and each arc-shaped sliding groove (103) is slidably connected to a... An arc-shaped slider (104) is fixedly connected to an arc-shaped slide rail (105). A winding ring (106) is slidably connected inside the arc-shaped slide rail (105). A coil groove (107) is opened along its circumference on the winding ring (106). A winding hole (108) is opened along its radial direction on the winding ring (106). An obliquely arranged magnetic core through-hole (109) is opened along its axial direction on the winding ring (106). A revolution drive assembly (500) that is connected to the lifting platform (101) and a rotation drive assembly (600) that is connected to the winding ring (106) are fixedly installed on the arc-shaped slider (104).

2. The inductor dual-station winding device according to claim 1, characterized in that: The tension sensing component (700) is installed inside the winding hole (108). The tension sensing component (700) is electrically connected to a control system. The control system is electrically connected to the revolution drive component (500) and the rotation drive component (600).

3. The inductor dual-station winding device according to claim 1, characterized in that: The lifting drive assembly (200) includes a drive screw (201), the bottom end of which is rotatably connected to the inner bottom surface of the storage container (100). A top cover (202) is fixedly installed on the top surface of the storage container (100). A lifting hole (203) is provided in the center of the top cover (202). A lifting drive motor (204) is fixedly installed on the top cover (202). The output shaft of the lifting drive motor (204) is coaxially fixedly connected to the top of the drive screw (201). A lifting platform (101) is installed below the top cover (202). A spiral hole (205) is provided on the lifting platform (101) for threaded transmission connection with the drive screw (201).

4. The inductor dual-station winding device according to claim 1, characterized in that: The magnetic core fixing assembly (300) includes two coaxially symmetrically arranged telescopic members (301). The telescopic members (301) are respectively fixedly installed on two symmetrically arranged fixing frames (102). The ends of the two telescopic members (301) that are close to each other are telescopic ends. Each telescopic end of the telescopic member (301) is fixedly installed with a clamping block (302) that matches the shape of the outer ring of the magnetic core (900).

5. The inductor dual-station winding device according to claim 1, characterized in that: The wire end fixing assembly (400) includes a wire end positioning hole (401) on the fixing frame (102), a threaded hole (402) communicating with the wire end positioning hole (401) on the fixing frame (102), a locking screw (403) being threadedly connected inside the threaded hole (402), and a knob (404) being fixedly connected to the outer end of the locking screw (403).

6. The inductor dual-station winding device according to claim 1, characterized in that: The revolution drive assembly (500) includes a first waterproof motor (501), which is fixedly mounted on the arc-shaped slider (104). A first drive gear (502) is fixedly mounted on the output shaft of the first waterproof motor (501). An arc-shaped rack (503) is fixedly mounted on the lifting platform (101) corresponding to the first drive gear (502). The first drive gear (502) meshes with the arc-shaped rack (503), and the center of the arc-shaped rack (503) coincides with the center of the arc-shaped groove (103).

7. The inductor dual-station winding device according to claim 1, characterized in that: The revolution drive assembly (500) includes a first waterproof motor (501), which is fixedly mounted on the arc-shaped slider (104). A first drive gear (502) is fixedly mounted on the output shaft of the first waterproof motor (501). An arc-shaped tooth groove (504) is provided on the lifting platform (101) corresponding to the first drive gear (502). The first drive gear (502) meshes with the arc-shaped tooth groove (504), and the center of the arc-shaped tooth groove (504) coincides with the center of the arc-shaped slide groove (103).

8. The inductor dual-station winding device according to claim 1, characterized in that: The self-rotating drive assembly (600) includes a second waterproof motor (601), which is fixedly mounted on the arc-shaped slider (104). A second drive gear (602) is fixedly mounted on the output shaft of the second waterproof motor (601). The end face of the winding ring (106) is provided with an annular tooth groove (603) corresponding to the second drive gear (602). A first clearance opening (604) is provided on the arc-shaped slide rail (105). The second drive gear (602) passes through the first clearance opening (604) and meshes with the annular tooth groove (603).

9. The inductor dual-station winding device according to claim 8, characterized in that: The arc-shaped slide rail (105) has several second clearance openings (605) evenly distributed along its length direction. Each of the arc-shaped slide rail (105) is rotatably connected to an auxiliary gear (606) corresponding to the second clearance opening (605). The auxiliary gear (606) passes through the second clearance opening (605) and meshes with the annular tooth groove (603).

10. An inductor dual-station winding device according to claim 2, characterized in that: The tension sensing assembly (700) includes two sets of symmetrically arranged pressure sensors (701). The pressure sensors (701) are symmetrically installed inside the winding hole (108). The ends of the pressure sensors (701) that are close to each other are the detection ends. The detection ends of the pressure sensors (701) are fixedly mounted with roller brackets (702). Rollers (703) are rotatably connected to the roller brackets (702).

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