Copper tube coil winding device and winding method

Abstract

This application provides a copper tube coil winding device and method, relating to the field of coil production equipment. The winding device includes a wire organizing module, a shaping module, and a winding assembly spaced apart along the unfolding direction of the copper tube. The wire organizing module drives the copper tube coil it carries to rotate, naturally unfolding and leading out the copper tube from a tangential direction of the coil, reducing the bending angle at the lead-out and preventing the copper tube from rotating around its own axial direction. This straightens the coiled copper tube, reducing the risk of cross-sectional deformation from the source and improving coil quality. The shaping module further constrains the cross-sectional shape of the copper tube, ensuring that the copper tube delivered to the winding assembly has a regular shape, improving coil quality and ensuring the performance of subsequent products such as pulse inductors and transformers.

Description

Technical Field

[0001] This application generally relates to the field of coil manufacturing equipment, and more specifically to a copper tube coil winding apparatus and winding method. Background Technology

[0002] Coil winding fixtures are key process equipment in the manufacturing of electromagnetic components such as motors, transformers, and inductors. They are used to wind wires or foil strips into specific shapes and sizes. In power equipment, high-energy physics experimental devices (such as particle accelerators), medical equipment (such as MRI magnets), military, and high-end industrial fields, coils with high current carrying capacity or special cooling requirements are often needed. These coils are typically wound using hollow copper tubes with rectangular or circular cross-sections. Water or other cooling media can flow inside the copper tubes to ensure temperature rise control requirements under high-power equipment operation.

[0003] When winding hollow copper tube coils, especially large, precision, and multi-turn coils (such as pulse inductors and magnetic field coils), the copper tube must be straightened and adjusted against the bending direction during the winding process from the coil spool. A large bending angle may cause severe cross-sectional deformation or even blockage of the internal flow channels, and there is also a risk of damaging the copper tube's insulation layer and the coil itself. Copper tubes drawn from cylindrical coils may twist during winding (common in the winding of square-section copper tubes). When winding coils of different shapes (such as disc-shaped coils and spring-shaped coils), custom-made production fixtures are required for each coil shape, and existing winding equipment lacks flexibility. These problems directly affect the coil's quality, performance, and manufacturing cost. If the coil deviates from the design requirements due to copper tube rotation or localized deformation, inconsistent insulation thickness at different locations may cause localized arcing during subsequent filling processes. Traditional winding processes and general-purpose winding fixtures face a series of severe challenges.

[0004] Therefore, there is a need to provide a copper tube coil winding apparatus and a winding method to at least partially solve the above problems. Summary of the Invention

[0005] The summary section introduces a series of simplified concepts, which will be further explained in detail in the detailed description section. This summary section is not intended to limit the key and essential technical features of the claimed technical solution, nor is it intended to determine the scope of protection of the claimed technical solution.

[0006] To at least partially address the aforementioned problems, a first aspect of this application provides a copper tube coil winding apparatus, including a winding assembly for winding a copper tube into a coil, the copper tube coil winding apparatus further comprising: A cable management module for supporting a copper cable reel, the module being configured to rotate with the reel to guide the copper tubing to unfold along a tangential direction of the reel; and The shaping module is used to shape and constrain the cross-section of the copper tube before feeding it to the winding assembly; The cable management module, the shaping module, and the winding assembly are spaced apart along the direction of copper tube unfolding to reduce the bending stress of the copper tube during the lead-out process.

[0007] According to this solution, the copper tube is straightened from its coiled state by the wire straightening module before winding to avoid twisting of the copper tube during the winding process. The shaping module adjusts the deformed parts of the copper tube to ensure that the copper tube meets the design requirements during winding. The functional modules are distributed along the direction of copper tube unfolding to minimize the bending stress of the copper tube during the lead-out process.

[0008] Optionally, the cable management module includes a support frame and a tray, the tray being mounted on the support frame and capable of rotating relative to the support frame about a rotation axis, the rotation axis being perpendicular to the plane in which the tray is located; During the winding of the copper tube coil, the copper tube coil is placed on the tray and rotates synchronously with the tray around the rotation axis.

[0009] According to this solution, the cable management module uses a tray to support the copper cable reel, and the tray drives the copper cable reel to rotate, allowing the coiled copper cable to be quickly unwound.

[0010] Optionally, the cable management module further includes a mounting shaft, through which the copper cable coil passes during the winding of the copper tube coil; The mounting shaft is fixedly installed to the support frame and distributed along the rotation axis. The mounting shaft is connected to the tray via a bearing. The tray has a through hole in the middle that allows the mounting shaft to pass through.

[0011] According to this solution, the cable management module positions the copper cable tray by mounting a shaft.

[0012] Optionally, the top of the support frame is provided with multiple sets of rollers, which are used to support the tray and guide the tray to rotate around the rotation axis.

[0013] According to this solution, the cable management module achieves smooth rotation of the tray through the rotating wheels; multiple sets of rotating wheels are connected to the tray on the same plane; the multiple sets of rotating wheels can be evenly distributed around the rotation axis or symmetrically distributed relative to the plane where the rotation axis is located, ensuring that the load is evenly transmitted to the support frame. Those skilled in the art can flexibly choose the arrangement of the rotating wheels.

[0014] Optionally, the shaping module includes a clamping plate assembly, which includes a first clamping plate and a second clamping plate that are detachably connected. The first clamping plate and the second clamping plate are connected to form a shaping channel for the copper tube to pass through. The cross-sectional shape of the shaping channel matches the cross-sectional shape of the copper tube. When the copper tube coil is wound, the first clamp and the second clamp clamp the copper tube passing through the shaping channel to constrain and adjust the cross-sectional shape of the copper tube.

[0015] According to this scheme, the shaping channel formed by splicing the first clamping plate and the second clamping plate adjusts the cross-sectional shape of the copper tube. The inner wall of the shaping channel squeezes the copper tube in the channel and slightly adjusts the shape of the copper tube to be consistent with the shape of the shaping channel. The shape of the copper tube is adjusted without damaging it, so as to ensure the quality of the coil wound later.

[0016] Optionally, the first clamping plate and the second clamping plate are connected by threaded fasteners and are aligned in a direction perpendicular to the extension direction of the shaping channel.

[0017] According to this solution, the first and second clamping plates are detachable. The grooved portions of the two clamping plates form a shaping channel after the clamping plates are aligned, reducing the manufacturing and assembly difficulty of the clamping plate assembly.

[0018] Optionally, the shaping module further includes a support frame, a sliding component, and a fixing frame. The clamping plate assembly is mounted to the fixing frame and is movable relative to the fixing frame. The fixing frame is mounted to the support frame via the sliding component, so that the clamping plate assembly can slide relative to the support frame. The shaping channel can be positionally adjusted in a plane perpendicular to the copper tube unfolding direction.

[0019] According to this solution, the clamping plate assembly can move in a plane perpendicular to the unfolding direction of the copper tube, which makes it easy to adjust the position of the shaping channel to be consistent with the unfolding direction of the copper tube, thus avoiding damage to the insulation layer of the copper tube due to excessive bending angle and local stress during unfolding and shaping.

[0020] Optionally, the sliding assembly includes a matching guide shaft and a slider, the fixing bracket is fixedly connected to the slider, and the clamping plate assembly and the fixing bracket slide along the guide shaft with the slider.

[0021] According to this solution, the sliding component is specifically composed of a guide shaft and a slider. Those skilled in the art can flexibly select the number of guide shafts and the material of the sliding component according to the actual situation.

[0022] Optionally, the fixing frame includes two upright plates arranged opposite each other, the clamping plate assembly is clamped between the two upright plates, the upright plates are provided with slides extending along the adjustment direction, the slides are connected to limit locking devices, and the clamping plate assembly is located between two sets of limit locking devices spaced apart along the adjustment direction; The adjustment direction, the extension direction of the shaping channel, and the extension direction of the guide shaft are all perpendicular to each other.

[0023] According to this solution, a specific method for moving the clamping plate assembly in a plane perpendicular to the unfolding direction of the copper tube is given.

[0024] A second aspect of this application also provides a method for winding a copper tube coil, applied to the copper tube coil winding apparatus described in the first aspect of this application, the method comprising the following steps: The copper tube coil is installed on the wire management module of the copper tube coil winding device. The wire management module drives the copper tube coil to rotate, guiding the copper tube to unfold along a tangential direction of the copper tube coil. The copper tube is subjected to cross-sectional shaping and constraint by the shaping module, and then the copper tube is sent to the winding assembly for coil winding.

[0025] This application provides a copper tube coil winding device and method. The copper tube is naturally unwound and led out from the tangential direction of the coil by the wire management module, reducing the bending angle and preventing the copper tube from rotating around its own axis. This straightens the coiled copper tube, reducing the risk of cross-sectional deformation from the source and improving the coil quality. The shaping module further constrains the cross-sectional shape of the copper tube, ensuring that the shape of the copper tube delivered to the winding assembly is regular, improving the coil quality and ensuring the performance of subsequent products such as pulse inductors and transformers.

[0026] Other features and advantages of this application will be set forth in the following description and will be apparent in part from the description or may be learned by practicing the application. The objectives and other advantages of this application may be realized and obtained by means of the structures pointed out in the description and the accompanying drawings. Attached Figure Description

[0027] The following drawings, illustrating embodiments of this application, are incorporated herein by reference and are used to understand this application. The drawings illustrate embodiments of this application and their descriptions, serving to explain the principles of this application. In the drawings, Figure 1 This is a schematic diagram of a copper tube coil winding apparatus according to a preferred embodiment of this application; Figure 2 This is a three-dimensional structural diagram of the wire management module in a copper tube coil winding apparatus according to a preferred embodiment of this application; Figure 3 for Figure 2 A side view of the central linear module. Figure 4 This is a three-dimensional structural diagram of the shaping module in a copper tube coil winding apparatus according to a preferred embodiment of this application. Figure 5 for Figure 4 A magnified schematic diagram of a portion of the shaping module; Figure 6 for Figure 4 A three-dimensional structural diagram of the first clamping plate; and Figure 7 for Figure 1 A top view of the structure of the centering line module and the shaping module. Explanation of reference numerals in the attached figures: 100. Copper tube coil winding device; 10. Wire management module; 11. Support frame; 12. Tray; 121. Through hole; 13. Mounting shaft; 14. Bearing; 15. Rotary wheel; 16. Spoke; 17. Strip hole; 20. Shaping module; 21. Clamping plate assembly; 211. First clamping plate; 212. Second clamping plate; 213. Shaping channel; 214. Guide section; 22. Support frame; 23. Sliding assembly; 231. Guide shaft; 232. Slider; 24. Fixing frame; 25. Detachable connector; 30. Winding assembly; 200. Copper tube coil; 300. Copper tube; X. Rotation axis; Y. Copper tube unfolding direction; Z. First sliding direction; W. Second sliding direction. Detailed Implementation

[0028] In the following description, numerous specific details are set forth to provide a more thorough understanding of this application. However, it will be apparent to those skilled in the art that embodiments of this application may be practiced without one or more of these details. In other instances, certain technical features well-known in the art have not been described to avoid confusion with embodiments of this application.

[0029] To fully understand the embodiments of this application, detailed structures will be presented in the following description. Obviously, the implementation of the embodiments of this application is not limited to the specific details familiar to those skilled in the art. Preferred embodiments of this application are described in detail below; however, other embodiments may exist besides these detailed descriptions, and should not be construed as being limited to the embodiments presented herein.

[0030] It should be understood that the terminology used herein is intended only to describe particular embodiments and is not intended to limit the scope of this application. The singular forms “a,” “an,” and “the” are also intended to include the plural forms unless the context clearly indicates otherwise. When the terms “comprising” and / or “including” are used in this specification, they indicate the presence of the stated features, integrals, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or combinations thereof. The terms “upper,” “lower,” “front,” “rear,” “left,” “right,” and similar expressions used in this application are for illustrative purposes only and are not intended to be limiting.

[0031] Ordinal numbers such as “first” and “second” used in this application are merely identifiers and have no other meaning, such as a specific order. Moreover, for example, the term “first component” does not imply the existence of a “second component”, and the term “second component” does not imply the existence of a “first component”.

[0032] In this document, terms such as “equal” and “same” are not strict mathematical and / or geometric limitations, but also include errors that are understandable to those skilled in the art and permissible in manufacturing or use.

[0033] Unless otherwise stated, the numerical ranges in this document include not only the entire range within its two endpoints, but also the subranges contained therein.

[0034] The specific embodiments of this application will be described in more detail below with reference to the accompanying drawings, which illustrate representative embodiments of this application and are not intended to limit this application.

[0035] Reference Figure 1 and Figure 7 According to an embodiment of this application, a copper tube coil winding device 100 is arranged in sequence along the unfolding direction Y of the copper tube 300, including a wire management module 10, a shaping module 20, and a winding assembly 30. After the copper tube 300 is led out from the copper tube coil 200, it first passes through the wire management module 10 to achieve natural unfolding, and then enters the shaping module 20 for cross-sectional shaping and constraint. The adjusted copper tube is finally sent to the winding assembly 30 for coil winding.

[0036] See Figure 1 The three main functional modules, namely the cable management module 10, the shaping module 20, and the winding assembly 30, are distributed at appropriate intervals along the unfolding direction Y so that the copper tube 300 can maintain a relatively straight extension between the modules and avoid large bending of the copper tube 300 due to the modules being too close together.

[0037] In actual arrangement, the distance between the wire management module 10 and the shaping module 20 can be set to exceed the radius of the copper coil 200, for example. The distance between the shaping module 20 and the winding assembly 30 can be adjusted appropriately according to the actual situation of the wound coil to ensure that the copper tube 300 maintains a stable cross-sectional shape before entering the winding assembly 30. It can be understood that a stable cross-sectional shape includes the copper tube not undergoing bending deformation or torsional deformation.

[0038] The winding assembly 30 can be selected from conventional coil winding mechanisms in the art. For example, its design can refer to a horizontal or vertical winding machine, mainly including a winding die and a drive mechanism for rotating the winding die. During the winding process, driven by the drive mechanism, the winding die rotates and winds the copper tube 300 led out through the shaping module 20 onto the winding die according to the design requirements, thereby forming a copper tube coil with the required number of turns and shape. It is understood that the winding die can be flexibly replaced according to different coil size requirements.

[0039] See Figure 1 In this embodiment, the winding assembly 30 includes a frame, a drive motor, and a winding die. The drive motor is mounted on the frame, and the winding die is connected to the output end of the drive motor. An inlet section is also provided on the frame, fixed to the frame and located on the side of the winding die. The copper tube output from the shaping module 20 is fed to the winding die for winding after passing through the inlet section. It should be noted that the inlet section is suitable for winding disc-shaped coils. The inlet section has an inlet channel, which can prevent the copper tube from twisting during winding, ensuring that the coil turn spacing and thickness meet design requirements.

[0040] In actual production, the quality of coil winding directly affects the insulation layer filling dimensions in subsequent production processes. If the coil deviates from the design requirements due to copper tube rotation or local deformation, localized arcing may occur after filling due to inconsistent insulation layer thickness at different locations. The copper tube coil winding device 100 of this application can effectively improve the coil yield.

[0041] Reference Figures 1 to 3 In the embodiment shown, the cable management module 10 includes a support frame 11, a tray 12, a mounting shaft 13, a bearing 14, and several sets of rollers 15.

[0042] To facilitate transport, copper tubes are typically wound onto a wire spool after production. The overall function of the wire management module 10 is to support the copper wire spool 200 and rotate the entire copper wire spool 200, guiding the copper tube 300 to unfold smoothly along the tangential direction of the copper wire spool 200, thereby minimizing the bending angle and torsional stress of the copper tube 300 during lead-out.

[0043] like Figure 1As shown, the support frame 11 is the basic load-bearing structure of the entire cable management module 10. It has a frame-like layout and can be made of materials such as steel profiles and steel pipes, connected by welding or bolts. It has sufficient rigidity to support the weight of the copper cable reel 200 filled with copper pipes 300. In the illustrated example, the support frame 11 is constructed as a tripod structure.

[0044] Preferably, the bottom of the support frame 11 can be connected to a moving device such as universal casters to facilitate flexible adjustment of the position of the entire support frame 11. The bottom of the support frame 11 can also be provided with leveling feet (not shown) to adjust the level of the support frame 11 during installation, ensuring that the rotation plane of the tray 12 is in a horizontal state and preventing the copper cable tray 200 from tilting during rotation.

[0045] See Figure 1 and Figure 3 The top of the support frame 11 is provided with a support beam, and multiple sets of rollers 15 are arranged on the support beam. The rollers 15 are horizontally installed on the top of the support frame 11 by means of axle pins, and the top surface of the rollers 15 maintains rolling contact with the bottom surface of the tray 12.

[0046] Mounting shaft 13 is fixedly mounted to support frame 11, and its axis is the rotation axis, which extends vertically. During the winding of the copper tube coil, the copper tube coil 200 passes through mounting shaft 13, that is, the center hole of the copper tube coil 200 is fitted onto mounting shaft 13. The winding axis of the copper tube coil 200 is parallel to the axis of mounting shaft 13 (i.e., the rotation axis X).

[0047] In this embodiment, the supporting beam is a horizontally arranged ring beam, the central axis of the ring beam roughly coincides with the rotation axis X, and multiple sets of rotating wheels 15 are evenly distributed along the circumference, with the axis of the rotating wheels 15 roughly arranged along the radial direction of the supporting beam.

[0048] The number of sets of rollers 15 is preferably three or four, and they are evenly distributed on the support beam along the same circumference with the rotation axis X as the center, so as to ensure uniform support for the pallet 12 and prevent the pallet 12 from radially shifting during rotation. The outer ring of the rollers 15 is covered with polyurethane material, which allows the pallet 12 carrying the copper cable tray 200 to rotate more smoothly.

[0049] like Figure 2 In the embodiment shown, the tray 12 is generally circular, with a diameter slightly larger than the outer diameter of the copper cable tray 200, to ensure that the copper cable tray 200 can be stably placed on the tray 12 without radial displacement.

[0050] The upper surface of the tray 12 can be provided with anti-slip textures or a rubber pad to increase the friction between the tray 12 and the bottom of the copper cable reel 200, preventing relative slippage of the copper cable reel 200 during winding. In this embodiment, the tray 12 is provided with strip-shaped holes 17, and multiple strip-shaped holes 17 are circumferentially distributed at intervals around the axis of rotation. The strip-shaped holes 17 extend approximately along the radial direction of the tray 12 and are used to install spokes 16 (see...). Figure 2 The spokes 16 serve two purposes: firstly, to elevate the copper cable reel 200, making it easier to install and remove; and secondly, the portion of the spokes 16 extending out onto the tray 12 can act as a handle for rotating the tray 12.

[0051] The outer periphery of the tray 12 may also be provided with an upward-folding annular guard, which can prevent the copper cable tray 200 from sliding outward due to inertia during rotation. The bottom surface of the tray 12 maintains rolling contact with the top surface of the roller 15, thereby forming a rotational support for the tray 12, so that the tray 12 can still rotate smoothly under the action of a small driving force after bearing the copper cable tray 200.

[0052] The bottom of the mounting shaft 13 can be fixed to the center of the support frame 11 via a threaded connection or flange connection, or it can be directly welded in place. See also Figure 1 The tray 12 can rotate freely around the rotation axis X, and the copper pipe coil 200 rotates synchronously with the tray 12. The copper pipe 300 is led out from the outer periphery of the copper pipe coil 200 in a tangential direction, eliminating the need for the copper pipe 300 to twist around its own axis when it is led out, thus fundamentally eliminating the torsional stress of the copper pipe 300.

[0053] The tray 12 has a through hole 121 in the middle, the diameter of which is slightly larger than the outer diameter of the mounting shaft 13 to allow the mounting shaft 13 to pass through the through hole 121. The tray 12 is connected to the mounting shaft 13 by a bearing 14. Specifically, the bearing 14 can be installed between the inner wall of the through hole 121 of the tray 12 and the outer wall of the mounting shaft 13, so that the tray 12 can rotate freely and smoothly relative to the mounting shaft 13 about the rotation axis X.

[0054] A limiting baffle (not shown) may be provided at the upper end of the mounting shaft 13. The limiting baffle is movably connected to the mounting shaft 13 to prevent the copper cable coil 200 from moving along the extension direction of the mounting shaft 13. The diameter of the mounting shaft 13 is selected according to the size of the center hole of the copper cable coil 200.

[0055] In other embodiments of this application, the cable management module may include a support frame, a tray, a mounting shaft, a drive device, and several sets of wheels. The drive device is mounted to the support frame, the mounting shaft is fixed to the surface of the tray for mounting copper cable reels, the tray is connected to the support frame via the wheels, and the tray is also connected to the output end of the drive device. The drive device drives the tray to rotate relative to the support frame around a rotation axis. The drive device may be an electrical control device such as a motor, thereby enabling automated control of the cable management module.

[0056] Reference Figures 4 to 6 In the illustrated embodiment, the shaping module 20 includes a support frame 22, a sliding component 23, a fixing frame 24, a clamping plate assembly 21, and a detachable connector 25. The main function of the shaping module 20 is to perform cross-sectional shaping constraints on the copper tube 300 led out from the cable management module 10, so as to correct slight cross-sectional deformations that may occur during the lead-out and transport process of the copper tube 300, and maintain the regular cross-sectional shape of the copper tube 300, so as to provide the winding assembly 300 with a dimensionally stable copper tube 300.

[0057] Reference Figure 5 and Figure 6 The clamping plate assembly 21 is the core shaping component of the shaping module 20, which includes a detachably connected first clamping plate 211 and second clamping plate 212. The first clamping plate 211 and the second clamping plate 212 can be made of tool steel or quenched and tempered alloy steel, and their contact surfaces (working surfaces) with the copper tube 300 are precision ground to ensure that the shape adjustment of the copper tube 300 will not scratch the surface of the copper tube 300 and its insulation layer.

[0058] The inner side of the first clamping plate 211 is provided with a first semi-groove, and the inner side of the second clamping plate 212 is provided with a second semi-groove corresponding to the first semi-groove. When the first clamping plate 211 and the second clamping plate 212 are engaged and connected, the first semi-groove and the second semi-groove together form a shaping channel 213. The shaping channel 213 extends along the unfolding direction Y of the copper tube 300, and the cross-sectional shape of the shaping channel 213 matches the target cross-sectional shape of the copper tube 300.

[0059] Preferably, the mating direction of the first clamping plate 211 and the second clamping plate 212 is perpendicular to the extension direction of the shaping channel 213.

[0060] In this embodiment, the inlet end of the shaping channel 213 is provided with a guide section 214 with a slightly larger cross-sectional area. The inner wall surface of the guide section 214 includes a curved section. The deformed part of the copper tube 300 is not consistent with the cross-sectional shape of the shaping channel 213. The deformed part can be gradually adjusted by the guide section 214 so that it can enter the shaping channel 213. Furthermore, the outlet end of the shaping channel 213 can also be provided with a chamfer or arc transition to avoid the copper tube 300 being subjected to secondary compression when it exits the shaping channel 213.

[0061] In this embodiment, for a rectangular cross-section copper tube 300, the cross-section of the shaping channel 213 is rectangular, and the clearance between its inner cross-sectional dimensions and the outer cross-sectional dimensions of the copper tube 300 is controlled between 0.05mm and 0.2mm. For a circular cross-section copper tube 300, the cross-section of the shaping channel 213 is circular, and the clearance is also controlled within the above range. The length of the shaping channel 213 (i.e., the dimension along the unfolding direction Y) exceeds three times the outer diameter or outer side length of the copper tube 300 to ensure sufficient guiding constraint length and prevent the copper tube 300 from deflecting within the shaping channel 213.

[0062] See Figure 5 and Figure 6 The first clamping plate 211 and the second clamping plate 212 are detachably connected by fastening bolts. During installation, the copper tube 300 is first inserted into the first or second half-groove, and then the two clamping plates are joined together and the fastening bolts are tightened to clamp the copper tube 300. Alternatively, after the first clamping plate 211 and the second clamping plate 212 are installed and fixed, the copper tube 300 is inserted into the shaping channel 213 through the guide section 214.

[0063] The first clamp 211 and the second clamp 212 of different sizes can be replaced according to the specifications of the copper tube 300 to adapt to copper tubes 300 with different cross-sectional specifications, thereby improving the versatility of the device.

[0064] Reference Figure 4 and Figure 5 The support frame 22 serves as the basic support structure for the shaping module 20. The clamping plate assembly 21 is mounted to the fixing frame 24 and can move relative to the fixing frame 24. The fixing frame 24 is mounted to the support frame 22 via the sliding assembly 23. The fixing frame 24 can slide relative to the support frame 22, allowing the clamping plate assembly 21 to slide relative to the support frame 22. This allows for flexible adjustment of the position of the shaping channel 213 in the plane perpendicular to the copper tube unfolding direction Y.

[0065] The sliding assembly 23 is mounted on the support frame 22 and includes a cooperating guide shaft 231 and a slider 232. The guide shaft 231 is along a first sliding direction (i.e., Figure 4 The guide shaft 231 is fixedly installed on the support frame 22 in the Z direction (usually vertical). Both ends of the guide shaft 231 are fixed to the left and right end beams of the support frame 22, respectively. The left and right end beams are connected to the columns on the left and right sides of the support frame 22. Multiple adjustment holes are provided on the columns along the height direction. The left and right end beams are connected to the corresponding adjustment holes on the columns via threaded fasteners. This allows adjustment of the position of the guide shaft 231 in the height direction, enabling adjustment of the overall height of the shaping module 20 according to the site conditions, so that the axis of the shaping channel 213 is aligned with the unfolding direction Y of the copper tube 300.

[0066] like Figure 4 and Figure 5 As shown, the number of guide shafts 231 is preferably two, and the two guide shafts 231 are parallel to each other to ensure that the slider 232 slides smoothly and to prevent the slider 232 from rotating during the sliding process.

[0067] The slider 232 is mounted on the guide shaft 231 and can slide freely along the extension direction (Z direction) of the guide shaft 231. Preferably, the slider 232 can be locked at any position on the guide shaft 231 by adjusting the screw or locking handle. By adjusting the position of the slider 232 on the guide shaft 231, the position of the clamp assembly 21 along the first sliding direction Z can be adjusted.

[0068] The mounting bracket 24 is mounted to the slider 232 and slides synchronously with the slider 232 along the extension direction (Z direction) of the guide shaft 231. The mounting bracket 24 is provided with a guide groove or guide rail for mounting the detachable connector 25, and the clamping plate assembly 21 is connected to the mounting bracket 24 through the detachable connector 25.

[0069] The fixing frame 24 can be plate-shaped or frame-shaped, and the guide groove or guide rail extends along the second sliding direction W. Figure 4 In the illustrated embodiment, the second sliding direction W is aligned with the height direction, perpendicular to the first sliding direction Z, and simultaneously perpendicular to the copper tube unfolding direction Y. The fixing frame 24 includes two opposing upright plates, which are fixed to the slider 232. The upright plates are provided with slots extending along the second sliding direction W as guide grooves. A detachable connector 25 passes through the guide grooves on the upright plates and can slide relative to the fixing frame 24 along the W direction; it can then be locked by adjusting screws.

[0070] like Figure 4 As shown, the detachable connector 25 can be a screw and a nut. The clamping plate assembly 21 is installed (clamped) between two upright plates. Along the height direction (W), two screws are provided on the lower side of the clamping plate assembly 21 to support it, and two screws are also provided on the upper side to restrain it. The screws are fixed to the upright plates by nuts, and the clamping plate assembly 21 is held in place by four sets of screws and nuts. It can be understood that the position of the clamping plate assembly 21 is changed by sliding the screws in the waist hole, and the nuts, as limiting and locking devices, are connected to the screws to fix the relative position of the screws and the waist hole.

[0071] In summary, the position of the clamping plate assembly 21 in the first sliding direction Z is adjusted by the guide shaft 231 and the slider 232, the position of the clamping plate assembly 21 in the second sliding direction W is coarsely adjusted by the column and the end beams (left end beam and right end beam), and the position of the clamping plate assembly 21 in the second sliding direction W is finely adjusted by the detachable connector 25 and the fixing frame 24.

[0072] The shaping channel 213 of the clamping plate assembly 21 can be adjusted to any position in a plane (ZW plane) perpendicular to the copper tube unfolding direction Y, thereby ensuring that the axis of the shaping channel 213 is roughly consistent with the lead-out path of the copper tube 300, and ensuring that the copper tube 300 passes smoothly through the shaping channel 213.

[0073] This application also provides a method for winding a copper tube coil, which is implemented using the aforementioned copper tube coil winding apparatus 100, and specifically includes the following steps: The copper cable reel 200 is inserted through the mounting shaft 13, so that the center hole of the copper cable reel 200 fits into the mounting shaft 13. The copper cable reel 200 sits on the upper surface of the tray 12. The winding axis of the copper cable reel 200 is parallel to the rotation axis X (usually both are in the vertical direction).

[0074] Based on the specifications (cross-sectional shape and size) of the copper tube 300, select the corresponding first clamping plate 211 and second clamping plate 212, and install them onto the fixing frame 24 via the detachable connector 25. Insert the lead-out end of the copper tube 300 into the shaping channel 213, adjust the position of the slider 232 and the detachable connector 25 so that the axis of the shaping channel 213 is approximately the same as the lead-out path of the copper tube 300, and then lock all adjustment structures.

[0075] After the copper tube 300 is led out from the outlet end of the shaping channel 213, it is connected to the winding mold core of the winding assembly 30.

[0076] The end of the copper tube 300 can be fixed to the mold core, or an appropriate length of copper tube 300 can be pre-wound along the winding mold core to establish initial tension.

[0077] The working process of winding a coil using the copper tube coil winding device 100 described above is as follows: When the winding assembly 30 begins to rotate, a traction force along the unfolding direction Y is applied to the copper tube 300. Under the action of the traction force, the copper tube 300 is gradually drawn out from the outer periphery of the copper tube reel 200 along the tangential direction. Since the copper tube reel 200 is placed on the freely rotatable tray 12, when the copper tube 300 is drawn out, the copper tube reel 200 rotates synchronously with the tray 12, and the copper tube 300 always unfolds along the tangential direction of the outer periphery of the copper tube reel 200, achieving smooth drawing out without the copper tube 300 twisting around its own axis.

[0078] At the same time, the multiple sets of rollers 15 on the top of the support frame 11 provide uniform rolling support to the bottom surface of the tray 12, reducing the frictional resistance when the tray 12 rotates, ensuring the smooth rotation of the copper pipe coil 200, and preventing the copper pipe 300 from generating additional tensile stress due to excessive rotational resistance.

[0079] Sufficient spacing is maintained between the cable management module 10 and the shaping module 20 so that after the copper tube 300 is led out from the copper tube coil 200, it can transition to the unfolding direction Y with a small bending angle (usually not exceeding 15°), thus avoiding large bending deformation of the copper tube 300 in the lead-out section.

[0080] After the copper tube 300 enters the shaping channel 213, the first clamping plate 211 and the second clamping plate 212 constrain the cross-section of the copper tube 300, restoring and maintaining the cross-section of the copper tube 300 to the target shape. For a rectangular cross-section copper tube 300, the four inner walls of the shaping channel 213 simultaneously apply constraints to the four outer surfaces of the copper tube 300 to prevent the cross-section of the copper tube 300 from becoming elliptical or collapsing during the winding process. For a circular cross-section copper tube 300, the circular inner wall of the shaping channel 213 constrains the copper tube 300 around its entire circumference, achieving the same cross-section shaping effect.

[0081] The shaped copper tube 300 is output straight from the outlet end of the shaping channel 213 and transitions into the winding area of ​​the winding assembly 30 with a small bend angle.

[0082] The shaping module 20 applies shaping constraints to the copper tube 300, which not only corrects the cross-sectional shape of the copper tube 300, but also provides a certain directional guidance for the copper tube 300, so that the copper tube 300 can stably enter the winding assembly 30 at a predetermined angle, preventing the copper tube from twisting during transmission and improving the winding accuracy.

[0083] The winding assembly 30 continuously drives the winding die core to rotate, winding the copper tube 300 layer by layer onto the winding die core. During the winding process, as the copper tube 300 is continuously drawn out, the copper tube coil 200 rotates continuously with the tray 12, and the shaping module 20 continuously constrains the cross-section of the copper tube 300. The three modules work together to ensure the continuity and stability of the winding process.

[0084] During single-layer multi-turn winding, the axial direction of the coil is approximately parallel to the guide shaft 231. The copper tube located in the mold core continuously shifts, which also drives the slider 232 in the previous process to move along the guide shaft 231, so that the copper tube can always enter the winding assembly in a regular state.

[0085] During multi-layer winding, insulating material (such as epoxy glass cloth or polyimide film) can be laid between each layer of copper tube 300 according to process requirements to meet the insulation requirements of the coil. After winding is completed, the winding assembly 30 is turned off, and the copper tube 300 is demolded from the winding mold core to obtain the desired finished copper tube coil.

[0086] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used herein is for descriptive purposes only and is not intended to limit the scope of this application. Terms such as “setup” appearing herein can refer to either a component being directly attached to another component or a component being attached to another component via an intermediary. A feature described in one embodiment herein may be applied, alone or in combination with other features, to another embodiment, unless that feature is not applicable in that other embodiment or is otherwise stated.

[0087] This application has been described through the above embodiments; however, it should be understood that the above embodiments are for illustrative purposes only and are not intended to limit this application to the described embodiments. Those skilled in the art will understand that many more variations and modifications can be made based on the teachings of this application, and all such variations and modifications fall within the scope of protection claimed in this application.

Claims

1. A copper tube coil winding apparatus, comprising a winding assembly for winding a copper tube into a coil, characterized in that, The copper tube coil winding device also includes: A cable management module for supporting a copper cable reel, the module being configured to rotate with the reel to guide the copper tubing to unfold along a tangential direction of the reel; and The shaping module is used to shape and constrain the cross-section of the copper tube before feeding it to the winding assembly; The cable management module, the shaping module, and the winding assembly are spaced apart along the direction of copper tube unfolding to reduce the bending stress of the copper tube during the lead-out process.

2. The copper tube coil winding device according to claim 1, characterized in that, The cable management module includes a support frame and a tray. The tray is mounted on the support frame and can rotate relative to the support frame about a rotation axis. The rotation axis is perpendicular to the plane where the tray is located and parallel to the winding axis of the copper cable reel. During the winding of the copper tube coil, the copper tube coil is placed on the tray and rotates synchronously with the tray around the rotation axis.

3. The copper tube coil winding device according to claim 2, characterized in that, The cable management module also includes a mounting shaft, through which the copper tube coil passes during the winding of the copper tube coil. The mounting shaft is fixedly installed to the support frame and distributed along the rotation axis. The mounting shaft is connected to the tray via a bearing. The tray has a through hole in the middle that allows the mounting shaft to pass through.

4. The copper tube coil winding device according to claim 3, characterized in that, The top of the support frame is provided with multiple sets of rollers, which are used to support the tray and guide the tray to rotate around the rotation axis.

5. The copper tube coil winding apparatus according to any one of claims 1 to 4, characterized in that, The shaping module includes a clamping plate assembly, which includes a first clamping plate and a second clamping plate that are detachably connected. After the first clamping plate and the second clamping plate are connected, a shaping channel for the copper tube to pass through is formed. The cross-sectional shape of the shaping channel matches the cross-sectional shape of the copper tube. During the winding of the copper tube coil, the first clamp and the second clamp clamp the copper tube passing through the shaping channel to constrain and adjust the cross-sectional shape of the copper tube.

6. The copper tube coil winding device according to claim 5, characterized in that, The first clamping plate and the second clamping plate are connected by threaded fasteners and are aligned in a direction perpendicular to the extension direction of the shaping channel.

7. The copper tube coil winding device according to claim 6, characterized in that, The shaping module further includes a support frame, a sliding component, and a fixing frame. The clamping plate assembly is mounted to the fixing frame and can move relative to the fixing frame. The fixing frame is mounted to the support frame via the sliding component, so that the clamping plate assembly can slide relative to the support frame. The shaping channel can be positionally adjusted in a plane perpendicular to the copper tube unfolding direction.

8. The copper tube coil winding device according to claim 7, characterized in that, The sliding assembly includes a matching guide shaft and a slider, the fixing bracket is fixedly connected to the slider, and the clamping plate assembly and the fixing bracket slide along the guide shaft with the slider.

9. The copper tube coil winding device according to claim 7, characterized in that, The fixing frame includes two upright plates arranged opposite each other, the clamping plate assembly is clamped between the two upright plates, the upright plates are provided with slides extending along the adjustment direction, the slides are connected to limit locking devices, and the clamping plate assembly is located between two sets of limit locking devices that are spaced apart along the adjustment direction. The adjustment direction, the extension direction of the shaping channel, and the extension direction of the guide shaft are all perpendicular to each other.

10. A method for winding a copper tube coil, applied to the copper tube coil winding apparatus according to any one of claims 1 to 9, characterized in that, The method includes the following steps: The copper tube coil is installed on the wire management module of the copper tube coil winding device. The wire management module drives the copper tube coil to rotate, guiding the copper tube to unfold along a tangential direction of the copper tube coil. The copper tube is subjected to cross-sectional shaping and constraint by the shaping module, and then the copper tube is sent to the winding assembly for coil winding.

Images