Device for bending and winding a heating wire and control method thereof

Abstract

This invention relates to a device and control method for bending and winding heating wires, belonging to the technical field of heating wire processing equipment. It includes a frame and a bending and winding mechanism mounted thereon. The bending and winding mechanism includes an operating platform with a heating wire winder and a bending fixture arranged side-by-side on the platform. The bending fixture is driven by a bending servo motor to engage a bending moving die and a bending stationary die to complete the bending. The heating wire winder is driven by a winding servo motor to rotate the winding fixture. A wire guide is located on its side, and a constant force tensioning fixture is located at its rear end. A tray seat with lateral displacement driven by a feeding belt is located in front of the operating platform, and an electrical control box is located inside the frame. The constant force tensioning fixture and the wire guide ensure constant winding tension and uniform wire arrangement, achieving high-precision, high-efficiency, and automated processing of heating wire bending and winding.

Description

Technical Field

[0001] This invention relates to the field of heating wire processing equipment technology, specifically to a device and control method for bending and winding heating wires. Background Technology

[0002] Heating wires, including nickel-chromium alloy wires and iron-chromium-aluminum alloy wires, are processed by bending and winding, which are key steps in the manufacturing of electric heating elements. In existing heating wire (such as heating tubes and heating cores) manufacturing fields, the following technical challenges typically exist: 1. Separation of processes, resulting in low production efficiency: Traditional heating wire processing typically treats "bending" and "winding" as two independent processes, completed on two different machines (bending machine and winding machine). The heating wire needs to be manually transferred and clamped twice between the two processes, which is not only time-consuming and labor-intensive, but also involves many intermediate transfer links, making it difficult to achieve continuous production.

[0003] 2. Unstable winding tension and unstable coil quality: Existing winding equipment mostly uses simple mechanical friction or manual tensioning. During high-speed winding, the tension often fluctuates due to changes in the size of the wire spool or machine vibration, which can easily lead to uneven pitch and loose coils (commonly known as "tangled wires" or "collapse"), seriously affecting the heating uniformity and service life of the heating wire.

[0004] Third, low level of automation and great safety hazards: Traditional equipment relies heavily on manual operation of heating wires for alignment, bending and winding. Workers' hands are close to the mold and rotating mechanism, which poses a great safety hazard. In addition, it is highly dependent on the experience of the operators and is difficult to adapt to the needs of modern production of large batches and high quality. Summary of the Invention

[0005] This invention addresses the shortcomings of existing technologies by providing a device and control method for bending and winding heating wires. It integrates bending, winding, and tension control, solving the problems of low efficiency and unstable accuracy in traditional separate equipment. By integrating the bending and winding processes into the same station, secondary clamping errors are eliminated. A constant force tensioning fixture and a wire guide ensure constant winding tension and uniform wire arrangement, achieving high-precision, high-efficiency automated processing of heating wire bending and winding.

[0006] The above-mentioned technical problems of the present invention are mainly solved by the following technical solutions: A device for bending and winding heating wire includes a frame, the upper end of which is provided with a bending and winding mechanism. The bending and winding mechanism includes a heating wire winder for winding the heating wire, and a bending clamp for bending the heating wire is provided on the side of the heating wire winder.

[0007] The heating wire winder winds a straight heating wire into a spiral shape. The bending fixture bends the heating wire into a specific angle and shape.

[0008] Preferably, the heating wire winding device includes a winding base, a winding clamp on the winding base, a winding servo motor inside the winding base for driving the winding clamp to rotate and wind the heating wire, and a wire guide on the side of the winding clamp.

[0009] The winding fixture is driven to rotate by a winding servo motor to wind the heating wire. The wire guide works in conjunction with the winding fixture to ensure that the heating wire is arranged evenly and tightly, avoiding overlap or uneven spacing, and ensuring winding quality.

[0010] Preferably, the winding fixture has a constant force tensioning clamp mounted on the wire guide at its rear end. The constant force tensioning clamp provides a constant tension to the heating wire during the winding process, preventing uneven coil tightness, uneven screw diameter, or deformation due to thermal expansion and contraction caused by tension fluctuations.

[0011] Preferably, the frame is equipped with a power distribution box that is connected to the bending fixture, the wire guide, and the winding servo motor.

[0012] Preferably, the bending fixture includes a bending seat, a fixed bending die at the upper end of the bending seat, and a moving bending die on the side of the fixed bending die that cooperates with the fixed bending die to bend the heating wire. The moving bending die and the fixed bending die constitute a bending mold.

[0013] Preferably, the bending seat is equipped with a bending servo motor that drives the bending moving die to rotate and bend. The bending moving die is driven by the bending servo motor and rotates relative to the fixed bending die, thereby clamping and bending the heating wire.

[0014] Preferably, the bending fixture and the heating wire winding device are provided with a tray seat at the front end, a feeding rack is provided between the tray seat and the operating table, and a feeding belt is provided between the feeding rack and the tray seat to drive the tray seat to move laterally.

[0015] Preferably, the upper end of the frame is provided with a protective cover for the bending and winding mechanism, and a display screen is provided at the front upper part of the cover. The display screen is used to display parameters and status. A warning light is provided at the upper end of the cover. The warning light is used to indicate the operating or fault status.

[0016] Preferably, an operating platform is provided between the frame and the bending and winding mechanism for fixing the bending fixture and the heating wire winding device on the frame.

[0017] Preferably, the device comprises a lower frame, an operating platform, a bending fixture, and a heating wire winding device to bend and wind the heating wire. The bending fixture includes a fixed bending die and a moving bending die, and the heating wire winding device includes a winding fixture, a wire guide, and a constant force tensioning fixture. The device is characterized by the following steps: S1. Loading and Alignment: Place the heating wire in the bending fixture and align the ends of the heating wire.

[0018] S2, Bending Control: Controls the rotation of the bending moving die, and bends the heating wire through the cooperation of the bending moving die and the bending fixed die.

[0019] S3. Winding preparation: Insert one end of the bent heating wire into and clamp it in the winding fixture, and pass the other end through the ruby ​​wire nozzle and fix it on the constant force tensioning fixture on the wire guide.

[0020] S4. Winding and Constant Tension Control: Control the rotation of the winding fixture for winding, and simultaneously control the movement of the wire guide; during the winding and wire guide movement, control the constant force tensioning fixture to provide a constant tension force to overcome the springback stress during the winding of the heating wire, so that the heating wire maintains stable tension when passing through the ruby ​​wire nozzle at high speed, thus completing the winding of the heating wire.

[0021] The present invention can achieve the following effects: This invention provides a device and control method for bending and winding heating wires. Compared with existing technologies, it effectively solves the problems of bending accuracy and winding tension in the heating wire forming process by integrating a dual-station bending and winding process, servo precision control, constant force tension, and using ruby ​​wires. It effectively overcomes the shortcomings of existing technologies and produces the following beneficial effects: I. Integrated Process, Significantly Improving Production Efficiency: By placing the bending fixture and the heating wire winding device side by side on the same operating platform, a streamlined, one-stop processing system for "bending-winding" is achieved. After bending, there is no need for transfer between different machines; the wire is directly transferred to the winding station on the machine, greatly shortening processing auxiliary time and resulting in a qualitative leap in production efficiency.

[0022] 2. Avoid secondary clamping and improve product accuracy and consistency: Since bending and winding are completed on the same equipment, the bending reference and winding reference of the heating wire can be established uniformly or smoothly transitioned, eliminating the positioning error caused by secondary clamping in traditional processes, effectively ensuring the accuracy of bending angle and winding position, and improving product consistency.

[0023] III. Overcoming winding defects by combining constant tension with ruby ​​wires: Constant force tension clamp: Provides a constant tension force during the winding process, effectively counteracting the elastic rebound of the heating wire and avoiding problems such as loose coil and uneven pitch; Ruby wire tip: Utilizing the extremely high hardness and smoothness of ruby, the frictional resistance when the heating wire passes through at high speed is greatly reduced, preventing tension fluctuations caused by sudden changes in frictional force. The combination of these two factors ensures the tightness, uniformity, and forming quality of the spiral coil.

[0024] IV. Servo Precision Drive and Flexible Production Capability: The application of bending servo motors and winding servo motors replaces traditional mechanical limiters and pneumatic drives. Not only can the bending angle and number of winding turns be digitally and precisely set and steplessly adjusted, but the response speed is fast and the repeatability is high, enabling rapid adaptation to the production needs of heating wires of different specifications.

[0025] V. High degree of automation, reducing labor intensity and safety risks: Centralized control through the distribution box, combined with automatic lateral displacement feeding of the conveyor belt and pallet seat, and visual operation on the display screen, significantly reduces the frequency of manual intervention. Workers do not need to approach the rotating area of ​​the mold with their hands, which reduces labor intensity and completely eliminates safety hazards. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the structure of the present invention.

[0027] Figure 2 This is a schematic diagram of the bending and winding mechanism in this invention.

[0028] Figure 3 This is a schematic diagram of the bending fixture in this invention.

[0029] Figure 4 This is a schematic diagram of the heating wire winding device in this invention.

[0030] Figure 5 This is a schematic diagram of the frame structure in this invention.

[0031] In the diagram: 1. Cover; 2. Warning light; 3. Display screen; 4. Bending and winding mechanism; 5. Frame; 6. Feeding belt; 7. Bending fixture; 8. Tray seat; 9. Heating wire winding device; 10. Feeding rack; 11. Operating platform; 12. Bending seat; 13. Bending fixed die; 14. Bending moving die; 15. Bending servo motor; 16. Winding seat; 17. Winding fixture; 18. Wire guide; 19. Constant force tensioning fixture; 20. Winding servo motor; 21. Distribution box. Detailed Implementation

[0032] The technical solution of the present invention will be further described in detail below through embodiments and in conjunction with the accompanying drawings.

[0033] Example: Figure 1-5As shown, a device for bending and winding heating wire includes a frame 5, a bending and winding mechanism 4 at the upper end of the frame 5, and a cover 1 at the upper end of the frame 5 to protect the bending and winding mechanism 4. A display screen 3 is provided at the front end of the upper part of the cover 1. A warning light 2 is provided at the upper end of the cover 1. The bending and winding mechanism 4 includes an operating platform 11, on which a heating wire winder 9 for winding heating wire is provided. The heating wire winder 9 includes a winding seat 16, on which a winding clamp 17 is provided. A winding servo motor 20 for driving the winding clamp 17 to rotate and wind heating wire is provided inside the winding seat 16. A wire guide 18 is provided on the side of the winding clamp 17, and a constant force tension clamp 19 mounted on the wire guide 18 is provided at the rear end of the winding clamp 17. The heating wire winding device 9 has a bending fixture 7 on its side for bending the heating wire. The bending fixture 7 includes a bending seat 12, a bending fixed die 13 at the upper end of the bending seat 12, and a bending moving die 14 on the side of the bending fixed die 13 that cooperates with the bending fixed die 13 to bend the heating wire. A bending servo motor 15 is installed inside the bending seat 12 to drive the bending moving die 14 to rotate and bend. The operating platform 11 is used to fix the bending fixture 7 and the heating wire winding device 9 to the lower frame 5. The lower frame 5 has a power distribution box 21 that is connected to the phase circuit of the bending servo motor 15, the wire guide 18, and the winding servo motor 20. The bending fixture 7 and the heating wire winding device 9 have a tray seat 8 at their front end. A feeding rack 10 is provided between the tray seat 8 and the operating platform 11. A feeding belt 6 is provided between the feeding rack 10 and the tray seat 8 to drive the tray seat 8 to move laterally.

[0034] A control method for bending and winding a heating wire includes taking a heating wire from a tray 8 and placing it into a bending fixture 7 to align the end of the heating wire. A bending servo motor 15 rotates to drive a bending moving die 14, and the bending of the heating wire is completed by the combined action of a bending fixed die 13 and a bending moving die 14. Then, one end of the bent heating wire is inserted into a winding fixture 17 and clamped, while the other end passes through a ruby ​​wire nozzle and is fixed to a constant force tensioning fixture 19 on a wire guide 18. Finally, a winding servo motor 20 drives the winding fixture 17 to rotate to complete the winding of the heating wire.

[0035] Springback stress exists during winding, and if the tension is unstable, it can easily lead to coil loosening, uneven pitch, or out-of-tolerance outer diameter. The constant force tensioning clamp 19 provides a constant tension force throughout the movement of the wire guide and the rotation of the spindle via an internal spring or servo mechanism; the ruby ​​wire tip, due to its extremely high hardness and smooth surface, greatly reduces frictional resistance when the wire passes through at high speed, avoiding tension fluctuations caused by sudden changes in frictional force.

[0036] In summary, the device and control method for bending and winding heating wires integrate the two processes of "winding" and "bending" that traditionally require separate equipment into the same operating platform. Through the design of servo motors, constant force clamping, and automatic feeding, it achieves high efficiency, high precision, and automation in heating wire processing, reducing manual intervention and intermediate transfer links.

[0037] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0038] In summary, the above description is only a specific embodiment of the present invention, but the structural features of the present invention are not limited thereto. Any changes or modifications made by those skilled in the art within the scope of the present invention are covered by the patent scope of the present invention.

Claims

1. A device for bending and winding heating wire, characterized in that: Includes a frame (5), the upper end of which is provided with a bending and winding mechanism (4), the bending and winding mechanism (4) includes a heating wire winder (9) for winding the heating wire, and the side of the heating wire winder (9) is provided with a bending clamp (7) for bending the heating wire.

2. The apparatus for bending and winding heating wire according to claim 1, characterized in that: The heating wire winding device (9) includes a winding seat (16), a winding clamp (17) is provided on the winding seat (16), a winding servo motor (20) is provided inside the winding seat (16) to drive the winding clamp (17) to rotate and wind the heating wire, and a wire guide (18) is provided on the side of the winding clamp (17).

3. The apparatus for bending and winding heating wire according to claim 2, characterized in that: The winding clamp (17) is provided with a constant force tensioning clamp (19) mounted on the wire guide (18) at its rear end.

4. The apparatus for bending and winding heating wire according to claim 2, characterized in that: The frame (5) is equipped with a power distribution box (21) that is connected to the bending fixture (7), the wire guide (18), and the winding servo motor (20) in the circuit.

5. The apparatus for bending and winding a heating wire according to claim 1, characterized in that: The bending fixture (7) includes a bending seat (12), the upper end of the bending seat (12) is provided with a bending fixed mold (13), and the side of the bending fixed mold (13) is provided with a bending moving mold (14) that cooperates with the bending fixed mold (13) to bend the heating wire.

6. The apparatus for bending and winding a heating wire according to claim 5, characterized in that: The bending seat (12) is equipped with a bending servo motor (15) that drives the bending moving mold (14) to rotate and bend.

7. The apparatus for bending and winding a heating wire according to claim 1, characterized in that: The bending fixture (7) and the heating wire winding device (9) are provided with a tray seat (8) at the front end. A feeding rack (10) is provided between the tray seat (8) and the operating table (11). A feeding belt (6) is provided between the feeding rack (10) and the tray seat (8) to drive the tray seat (8) to move laterally.

8. The apparatus for bending and winding a heating wire according to claim 1, characterized in that: The upper end of the frame (5) is provided with a cover (1) to protect the bending and winding mechanism (4). The upper front end of the cover (1) is provided with a display screen (3) and a warning light (2) is provided at the upper end of the cover (1).

9. The apparatus for bending and winding a heating wire according to claim 1, characterized in that: An operating platform (11) is provided between the frame (5) and the bending and winding mechanism (4) for fixing the bending fixture (7) and the heating wire winding device (9) on the frame (5).

10. A control method for bending and winding a heating wire, comprising a lower frame (5), an operating table (11), a bending fixture (7), and a heating wire winding device (9) to form a device for bending and winding a heating wire, wherein the bending fixture (7) includes a bending fixed die (13) and a bending moving die (14), and the heating wire winding device (9) includes a winding fixture (17), a wire guide (18), and a constant force tensioning fixture (19), characterized in that, Includes the following steps: S1. Loading and Alignment: Place the heating wire in the bending fixture (7) and align the ends of the heating wire; S2, Bending control: Control the rotation of the bending moving die (14), and bend the heating wire through the cooperation of the bending moving die (14) and the bending fixed die (13); S3. Winding preparation: Insert one end of the bent heating wire into and clamp it in the winding fixture (17), and fix the other end through the ruby ​​wire nozzle to the constant force tensioning fixture (19) on the wire guide (18); S4. Winding and constant tension control: Control the rotation of the winding fixture (17) for winding, and control the movement of the wire guide (18) at the same time; during the winding and wire guide movement, control the constant force tensioning fixture (19) to provide constant tension to overcome the springback stress when the heating wire is wound, so that the heating wire maintains stable tension when passing through the ruby ​​wire nozzle at high speed, and completes the winding of the heating wire.

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