A core winding device for an electric machine and a method of using the same

Abstract

The application relates to the technical field of motor core winding, and discloses a motor core winding device and a use method thereof. A top-holding assembly is fixedly arranged on the outer side of the circumference of a stator core. A winding assembly is fixedly arranged on the top-holding assembly. The outer edge of the stator core is matched with protective plates which are symmetrically arranged on the front and back sides of the top-holding assembly. The winding assembly comprises a wire cylinder which rotates around the axis of the top-holding assembly. Symmetrically fixed tensioning assemblies corresponding to the wire cylinder are arranged on the winding assembly. Copper wires pass through the tensioning assemblies and the wire cylinder, are guided by the protective plates and the top-holding assembly, and are wound on the winding teeth. The top-holding assembly and the winding assembly are coaxially arranged. The follow-up tensioning assemblies are arranged to synchronously rotate along the winding track. The application overcomes the technical defects of the prior art, such as large winding tension fluctuation, disordered coil arrangement, easy deformation of the stator teeth, easy damage of the enameled wire and the like.

Description

Technical Field

[0001] This invention relates to the field of motor core winding technology, and in particular to a motor core winding device and its usage method. Background Technology

[0002] In an automatic winding device for producing motors, application number CN202420620681.0 discloses a rotor drive assembly installed on the upper side of the front end of the conveyor. Positioning brackets are fixedly installed on both sides of the front end of the conveyor. A V-shaped positioning frame is fixedly installed at the end of the positioning bracket away from the conveyor, allowing the two ends of the rotor core to roll into the V-shaped positioning frame, thus facilitating the positioning of the rotor core for assembly. In a motor stator core winding device, application number CN202423294691.9 discloses a winding mechanism between the frame and the gantry frame. The winding mechanism holds the stator core. A first cylinder is fixedly installed on the side of the gantry frame facing the frame. A suction box is fixedly installed at the power output end of the first cylinder. Multiple suction pipes are fixedly connected to one end of the suction box. A dust collector is fixedly installed on the gantry frame. An exhaust pipe is fixedly connected to the suction port of the dust collector, and one end of the exhaust pipe is fixedly connected to the suction box.

[0003] However, in actual use, existing iron core winding equipment mostly adopts a fixed stator and single-wire unidirectional winding mode. During the winding process, there is a lack of radial pre-support structure for the winding teeth, which makes the teeth prone to lateral bending deformation due to the tension of the copper wire. Moreover, conventional tensioning mechanisms are mostly external fixed tension adjustment structures, which cannot move synchronously with the winding rotation trajectory, causing the copper wire to experience sudden changes in tension as the rotation position changes, resulting in uneven coil density and tangled wire phenomena. At the same time, the traditional guide structure only has a single guide hole, and the inclination angle of the copper wire entering the wire cannot be kept consistent, which makes it easy to scratch the insulation layer of the enameled wire. Furthermore, there is no partitioned anti-cross-wire protection structure, which makes it easy to have mis-slotted winding defects. The overall winding consistency and yield rate are difficult to meet the production requirements of high-precision motor stators.

[0004] Therefore, the present invention proposes a winding device for an iron core of an electric motor and its method of use to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a winding device for an iron core of an electric motor and its method of use, so as to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a motor core winding device, comprising a support assembly, on which a stator core is positioned and installed, a top-holding assembly is fixedly assembled on the outer circumference of the stator core, and a winding assembly fixed relative to the position of the stator core is provided on the top-holding assembly. The stator core is uniformly provided with integrally formed winding teeth in the circumferential direction, and a winding groove is provided between two adjacent sets of winding teeth. The outer edge of the stator core is matched with protective plates symmetrically arranged on the front and rear sides of the top support assembly. The winding assembly includes a guide tube that rotates circumferentially around the axis of the top holding assembly, and tensioning components corresponding to the guide tube are symmetrically fixedly installed on the winding assembly. The copper wire passes through the tensioning component and the guide tube and is wound and assembled on the winding teeth based on the guidance of the protective plate and the top holding assembly. The tensioning component keeps the copper wire in a tensioned state at all times.

[0007] Preferably, the support assembly includes a fixed base, a servo motor is fixed at the center of the bottom of the fixed base, a turntable is fixedly installed through the fixed base at the output end of the servo motor, three sets of positioning columns are fixed on the top of the turntable along the circumferential direction, and the stator core is positioned and installed on the three sets of positioning columns, and a bearing ring for supporting the turntable is fixed on the top of the fixed base.

[0008] Preferably, the top support assembly includes an electric telescopic rod fixedly installed by a bracket. The output end of the electric telescopic rod is fixedly installed with a mounting base, and a base plate is fixedly installed at the middle position on the side of the mounting base near the stator core. A guide seat is slidably fitted on the outer side of the base plate. A pressure spring fixedly connected to the end of the base plate is fixed inside the guide seat. A limit seat is fixed at the outer end of the guide seat. Support plates are symmetrically installed on the top and bottom of the side of the mounting base near the stator core, and the end of each set of support plates is integrally formed with an arc-shaped guide portion facing the stator core.

[0009] Preferably, the limiting seat and the winding tooth are directly opposite each other, and the outer wall of the limiting seat is provided with a locking groove that fits with the outer end of the winding tooth, and the sliding stroke of the guide seat on the substrate matches the length of the winding tooth. The protective plate is fixedly installed by a bracket to fix its position. The protective plate is located on the outside of the winding teeth. Each set of protective plates has an integrally formed drainage part at the end near the limiting seat. The outer wall of the drainage part is set as an arc-shaped surface facing the winding groove.

[0010] Preferably, the distance between the two sets of support plates is slightly greater than the height of the winding teeth, and the outer wall of each set of arc-shaped guides is arc-shaped, and the wire tube and the arc-shaped guides correspond to each other.

[0011] Preferably, the winding assembly further includes a fixed ring and a rotating ring movably sleeved on the outside of the output end of the electric telescopic rod. The fixed ring and the rotating ring are fixedly connected by a bracket so that their positions are fixed relative to the stator core. A drive motor is fixed to the top of the fixed ring, and a main gear is fixed to the output end of the drive motor. A toothed ring that meshes with the main gear is fixed to the end face of the rotating ring, and the wire tube is symmetrically fixed on the upper and lower sides of the outer edge sidewall of the rotating ring.

[0012] Preferably, the tensioning assembly includes an outer cylinder fixed to the outer sidewall of the toothed ring, an inner rod guided inside the outer cylinder, an inner end of the inner rod extending into the outer cylinder and fixedly connected to a support spring, and the other end of the support spring fixed to the inner sidewall of the outer cylinder, and an outer end of the inner rod extending out of the outer cylinder and fixedly mounted on a mounting bracket, on which a lower guide wheel and an upper guide wheel are rotatably mounted via a pin.

[0013] Preferably, a miniature linear servo motor is bolted to the end of the outer cylinder away from the gear ring. The output shaft of the miniature linear servo motor faces the gear ring and is coaxially fixedly connected to an adjustable spring seat. The outer wall of the adjustable spring seat is slidably fitted to the inner wall of the outer cylinder. The end face of the adjustable spring seat near the gear ring is fixedly connected to a support spring. The outer wall of the inner rod is slidably fitted to the inner wall of the outer cylinder via a guide key. Pin mounting holes are symmetrically provided on both sides of the mounting bracket, and strain gauge force measuring devices are interference-fitted into the pin mounting holes. The pin shaft and the lower guide wheel are rotatably mounted in the middle of the strain gauge force measuring pin shaft via bearings. The upper guide wheel is rotatably mounted on the upper part of the mounting frame via the pin shaft and is located directly above the lower guide wheel. Both the lower and upper guide wheels have semi-circular guide grooves on their circumferential surfaces that match the outer diameter of the copper wire. The depth of the guide groove is 1 / 2 of the outer diameter of the copper wire, and the inner wall is coated with a polytetrafluoroethylene wear-resistant coating. The copper wire passes through the guide groove between the lower and upper guide wheels and through the wire cylinder, and is wound on the winding teeth. The wire cylinder has a threading hole that matches the copper wire.

[0014] This invention provides a method for using a motor core winding device, the steps of which are as follows: S1: The stator core to be wound is mounted on the three sets of positioning posts on the top of the turntable of the support assembly. Radial positioning is achieved by using the cooperation between the three sets of positioning posts and the center hole of the stator core. S2: Activate the electric telescopic rod of the top holding assembly, drive the mounting base to move towards the stator core, so that the engagement groove on the limit seat is tightly fitted with the outer end of the first winding tooth to be wound, the pressure spring is compressed and provides a continuous elastic holding force, and at the same time, the arc-shaped guide at the end of the support plate is aligned with the root of the winding tooth. S3: Pass the copper wire through the guide groove between the lower guide wheel and the upper guide wheel of the tensioning assembly in sequence, and then through the wire hole on the wire tube of the winding assembly, and fix the end of the copper wire at the root of the first winding tooth to be wound. S4: Start the drive motor, and drive the main gear and the gear ring to rotate at a constant speed around the axis of the electric telescopic rod through meshing transmission. This drives the two wire drums to make synchronous circular motion. The copper wire smoothly enters the winding groove under the continuous guidance of the guide part of the protective plate and the arc-shaped guide part of the support plate. At the same time, the tensioning component rotates synchronously with the rotating ring. The elastic extension and contraction of the support spring compensates for the tension change of the copper wire in real time, so that the copper wire maintains a constant tension state throughout the process and is evenly wound on the winding teeth. S5: When the first winding tooth is completed, the drive motor stops rotating, the electric telescopic rod retracts and drives the limit seat to disengage from the winding tooth, and the servo motor is started to drive the turntable to rotate at a preset indexing angle so that the next winding tooth to be wound is accurately aligned with the top holding component and the winding component. S6: Cyclic winding, repeat steps S2 to S5 until all winding teeth on the stator core have completed the winding operation.

[0015] The technical effects and advantages of this invention are as follows: 1. This invention movably mounts the winding assembly on the outside of the electric telescopic rod of the top holding assembly, achieving the three-axis coincidence of the winding rotation center, the iron core center, and the tooth end top holding center, completely eliminating the wire deviation problem caused by eccentric winding. At the same time, it shares the same reference mounting base, greatly reducing the space occupied by the equipment and the cumulative assembly error. It simplifies the transmission structure of the whole machine and ensures that the copper wire entry angle is constant throughout the entire process from the structural source.

[0016] 2. This invention adds a retractable limiting seat structure with a pressure spring. During winding, it elastically engages and presses against the end of the winding tooth, achieving flexible radial support throughout the winding process. This counteracts the lateral tension generated by the copper wire winding and prevents deformation of the winding tooth. Simultaneously, in conjunction with the precise indexing rotation of the bottom servo motor, the electric telescopic rod automatically retracts to avoid the winding after a single tooth is wound. This achieves fully automatic linkage of top holding positioning, winding operation, and indexing and repositioning. The working logic of this flexible support combined with automatic avoidance breaks through the technical limitations of traditional rigid positioning, which cannot adapt to continuous indexing winding, and solves the problem of core protection under high-precision dense winding conditions.

[0017] 3. This invention addresses the technical shortcomings of traditional tension adjustment mechanisms, which are fixed at the inlet end and cannot follow the winding trajectory. The constant change in copper wire length during rotation inevitably causes tension fluctuations. The entire tensioning assembly is directly fixed to the outside of the rotating toothed ring, rotating synchronously with the conductor cylinder. This achieves real-time synchronization between the tension adjustment point and the winding point. Dynamic adaptive tension compensation is achieved through the inner and outer cylinders combined with a support spring, maintaining a constant tension on the enameled copper wire throughout the entire process. Simultaneously, a multi-stage guiding structure with a tangential guide in the arc-shaped guide section and a smooth arc transition in the protective plate's drainage section, along with a gap-separating anti-cross-slot design in the protective plate, forms a closed-loop protective wiring system covering the entire process from inlet, tensioning, guiding, and winding. This effectively avoids mass production defects such as insulation layer damage, mis-slot winding, and uneven coil tension. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall first-view structure of the present invention; Figure 2 This is a schematic diagram of the overall second-view structure of the present invention; Figure 3 This is a partial first-view structural diagram of the present invention; Figure 4 This is a partial second-view structural diagram of the present invention; Figure 5 This is a schematic diagram of the assembly structure of the top support component, the winding component, and the protective plate of the present invention; Figure 6 This is a schematic cross-sectional view of the assembly structure of the top support component, winding component and protective plate of the present invention; Figure 7 This is a schematic diagram of the assembly structure of the top support component, winding component, tensioning component and protective plate of the present invention; Figure 8 This is a schematic cross-sectional view of the assembly structure of the top support component, winding component, tensioning component and protective plate of the present invention; Figure 9 For the present invention Figure 8 Enlarged structural diagram of section A in the middle.

[0019] In the diagram: 10. Support assembly; 1. Fixed base; 2. Servo motor; 3. Turntable; 4. Positioning column; 5. Bearing ring; 20. Stator core; 21. Winding gear; 30. Top holding assembly; 31. Electric telescopic rod; 32. Mounting base; 33. Support plate; 34. Arc-shaped guide part; 35. Base plate; 36. Guide seat; 37. Limiting seat; 38. Compression spring; 40. Winding assembly; 41. Fixed ring; 42. Drive motor; 43. Main gear; 44. Rotating ring; 45. Gear ring; 46. Wire cylinder; 50. Protective plate; 51. Drainage part; 60. Tensioning assembly; 61. Outer cylinder; 62. Inner rod; 63. Support spring; 64. Mounting bracket; 65. Lower guide wheel; 66. Upper guide wheel; 70. Copper wire. Detailed Implementation

[0020] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0021] like Figures 1 to 9As shown, this embodiment discloses a motor core winding device, including a support assembly 10, on which a stator core 20 is positioned and installed. A top-holding assembly 30 is fixedly mounted on the outer circumference of the stator core 20, and a winding assembly 40 is provided on the top-holding assembly 30 with a position fixed relative to the stator core 20. The stator core 20 has integrally formed winding teeth 21 evenly arranged in the circumferential direction, with winding grooves between adjacent sets of winding teeth 21. Protective plates 50 symmetrically arranged on the front and rear sides of the top-holding assembly 30 are matched and installed on the outer edge of the stator core 20. The winding assembly 40 includes a guide tube 46 that rotates circumferentially around the axis of the top-holding assembly 30, and a pair of guide tubes 46 are symmetrically fixedly mounted on the winding assembly 40. The copper wire 70 passes through the tensioning assembly 60 and the lead tube 46 and is wound onto the winding teeth 21 after being guided by the protective plate 50 and the top holding assembly 30. The tensioning assembly 60 keeps the copper wire 70 taut throughout the winding process. By setting the winding assembly 40 and the top holding assembly 30 on the same axis, the rotation center of the lead tube 46 is made to coincide with the center of the stator core 20, ensuring that the copper wire 70 can enter the winding slot at a constant angle. At the same time, the tensioning assembly 60 compensates for the tension changes of the copper wire 70 in real time during the winding process, effectively avoiding problems such as uneven coil tension and inaccurate number of turns caused by tension fluctuations in traditional winding devices, and significantly improving the winding quality and consistency of the stator core 20.

[0022] This embodiment differs from the conventional design in which the winding mechanism and stator support mechanism are separated in the prior art. It creatively sets the winding assembly 40 and the top holding assembly 30 on the same axis, so that the rotation center of the conductor tube 46 is completely coincident with the center of the stator core 20. This fundamentally eliminates the fluctuation of the copper wire entry angle caused by the change of winding position in the traditional eccentric winding method, ensuring that the copper wire 70 can enter the winding slot at a constant tangential angle. At the same time, the tensioning assembly 60, which rotates synchronously with the winding assembly 40, compensates for the tension change of the copper wire 70 in real time during the winding process. This effectively avoids the problems of uneven coil tightness, inaccurate number of turns, and messy arrangement caused by tension fluctuations in the traditional winding device, and significantly improves the winding quality and batch consistency of the stator core 20.

[0023] The support assembly 10 includes a fixed base 1, a servo motor 2 fixed at the center of the bottom of the fixed base 1, a turntable 3 fixedly mounted on the output end of the servo motor 2 through the fixed base 1, three sets of positioning posts 4 fixed along the circumferential direction on the top of the turntable 3, and the stator core 20 positioned on the three sets of positioning posts 4. A bearing ring 5 supporting the turntable 3 is fixed on the top of the fixed base 1. The inner ring of the bearing ring 5 is interference-fitted with the outer edge of the bottom of the turntable 3 to provide radial and axial support for the turntable 3. The servo motor 2 can precisely control the rotation angle and speed of the turntable 3, thereby realizing the indexing rotation of the stator core 20, so that each winding tooth 21 is aligned with the top holding assembly 30 and the winding assembly 40 in sequence for winding operation. The bearing ring 5 can effectively share the weight of the turntable 3 and the stator core 20, reduce the axial load of the servo motor 2, improve the stability and positioning accuracy of the turntable 3 rotation, and avoid winding deviation caused by turntable shaking.

[0024] The top support assembly 30 includes an electric telescopic rod 31 fixedly mounted by a bracket. A mounting base 32 is fixedly mounted on the output end of the electric telescopic rod 31. A base plate 35 is fixedly mounted on the middle position of the side of the mounting base 32 near the stator core 20. The base plate 35 is a rectangular plate. A guide seat 36 is slidably mounted on the outer side of the base plate 35. The guide seat 36 is a slide with a rectangular longitudinal section. A pressure spring 38 is fixedly connected to the end of the base plate 35 inside the guide seat 36. A sliding cavity matching the base plate 35 is opened inside the guide seat 36. One end of the pressure spring 38 is fixed to the bottom of the sliding cavity, and the other end of the pressure spring 38 is fixedly connected to the end of the base plate 35. A limit seat 37 is fixed to the outer end of the guide seat 36. Support plates 33 are symmetrically mounted on the top and bottom of the side of the mounting base 32 near the stator core 20. Each set of support plates 33 has an integrally formed arc-shaped guide portion 34 facing the stator core 20 at its end.

[0025] The electric telescopic rod 31 can drive the mounting base 32 to move towards the stator core 20, so that the limiting seat 37 fits tightly with the outer end of the winding tooth 21, providing radial support for the winding tooth 21 and preventing the winding tooth 21 from deforming due to the tension of the copper wire 70 during the winding process. At the same time, the pressure spring 38 can provide elastic buffering to avoid the limiting seat 37 causing rigid impact on the winding tooth 21, protecting the stator core 20 from damage. The support plate 33 and the arc-shaped guide part 34 can initially guide the copper wire 70 drawn from the wire tube 46, so that the copper wire 70 can accurately enter the entrance position of the winding groove.

[0026] The limiting seat 37 and the winding tooth 21 are directly opposite each other, and the outer wall of the limiting seat 37 is provided with an engaging groove that fits against the outer end of the winding tooth 21. The sliding stroke of the guide seat 36 on the substrate 35 matches the length of the winding tooth 21. The protective plate 50 is fixedly installed by a bracket to fix its position, and the protective plate 50 is located on the outside of the winding tooth 21. Each set of protective plates 50 has a drainage part 51 integrally formed at the end near the limiting seat 37, and the outer wall of the drainage part 51 is set as an arc-shaped surface facing the winding groove. A 0.5m gap is left between the inner side of the protective plate 50 and the outer end face of the winding tooth 21. With a gap of m to 1mm, the protective plate 50 can prevent the copper wire 70 from coming off the front and rear sides of the winding tooth 21 during the winding process. It can block the front and rear sides of the winding tooth 21 to prevent the copper wire 70 from accidentally entering other winding slots. Moreover, the protective plate 50 has a guiding effect on the copper wire 70, which greatly reduces the friction between the protective plate 50 and the copper wire 70. The arc-shaped surface of the guide part 51 can smoothly guide the copper wire 70 into the winding slot, avoiding friction between the copper wire 70 and the edges of the winding tooth 21, which would cause damage to the insulation layer. This effectively improves the safety and reliability of the winding.

[0027] The distance between the two sets of support plates 33 is slightly greater than the height of the winding teeth 21, with a difference of 2mm to 3mm. This ensures that the support plates 33 do not interfere with the stator core 20, while also effectively limiting the upper and lower limits of the copper wire 70 to prevent it from jumping up and down during winding. Furthermore, the outer wall of each set of arc-shaped guides 34 is a smooth arc surface, and the center of the arc surface coincides with the axis of the top support assembly 30. The wire tube 46 and the arc-shaped guides 34 are directly opposite each other, ensuring that the copper wire 70 remains stable throughout the entire rotation of the winding assembly 40. The guide 36 maintains a tangential relationship with the arc-shaped guide 34, ensuring that the entry angle of the copper wire 70 remains constant. This allows the copper wire 70, drawn from the conductor tube 46, to enter the winding groove along the tangential direction of the arc-shaped guide 34, resulting in a more neat and compact coil arrangement. The engaging groove on the limiting seat 37 can form a precise positioning fit with the winding tooth 21, preventing the winding tooth 21 from shifting circumferentially during winding. The sliding stroke of the guide seat 36 matches the length of the winding tooth 21, ensuring that the pressure spring 38 can provide a stable holding force throughout the winding process.

[0028] The winding assembly 40 also includes a fixed ring 41 and a rotating ring 44 movably sleeved on the outside of the output end of the electric telescopic rod 31. The fixed ring 41 and the rotating ring 44 are fixedly connected by a bracket, so that their positions are fixed relative to the stator core 20. A drive motor 42 is fixed to the top of the fixed ring 41, and a main gear 43 is fixed to the output end of the drive motor 42. A gear ring 45 that meshes with the main gear 43 is fixed to the end face of the rotating ring 44. The wire tube 46 is symmetrically fixed on the upper and lower sides of the outer edge sidewall of the rotating ring 44, and the axis of the wire tube 46 is parallel to that of the rotating ring 44. With the radial directions overlapping, during use, the drive motor 42 drives the rotating ring 44 to rotate around the axis of the electric telescopic rod 31 through the meshing transmission of the main gear 43 and the gear ring 45. This drives the two guide tubes 46 to make synchronous circular motion, realizing bidirectional winding of the winding teeth 21, which greatly improves the winding efficiency. The design of the fixed ring 41 and the rotating ring 44 being movably sleeved on the outside of the output end of the electric telescopic rod 31 allows the winding assembly 40 and the top holding assembly 30 to share the same axis, simplifying the overall structure of the device while ensuring winding accuracy.

[0029] It is worth noting that during the winding process of the winding assembly 40, the electric telescopic rod 31 synchronously drives the mounting base 32 to move back and reset. During this process, as the support plate 33 retracts, the copper wire 70 can be evenly wound on the winding teeth 21.

[0030] The tensioning assembly 60 includes an outer cylinder 61 fixed to the outer sidewall of the toothed ring 45. An inner rod 62 is guided inside the outer cylinder 61. The inner end of the inner rod 62 extends into the outer cylinder 61 and is fixedly connected to a support spring 63. The other end of the support spring 63 is fixed to the inner sidewall of the outer cylinder 61. The outer end of the inner rod 62 extends out of the outer cylinder 61 and is fixedly mounted on a mounting bracket 64. A lower guide wheel 65 and an upper guide wheel 66 are rotatably mounted on the mounting bracket 64 via a pin. Guide grooves matching the outer diameter of the copper wire 70 are formed on the circumferential surfaces of both the lower guide wheel 65 and the upper guide wheel 66. The copper wire 70 passes between the lower guide wheel 65 and the upper guide wheel 66 and through the wire tube 46, and is wound around the winding teeth 21. The wire tube 46 has openings... There is a threading hole that matches the copper wire 70. When the tension of the copper wire 70 increases, it will pull the upper guide wheel 66 and the lower guide wheel 65, causing the inner rod 62 to move into the outer cylinder 61 and compress the support spring 63, thereby absorbing the tension peak. When the tension of the copper wire 70 decreases, the support spring 63 will push the inner rod 62 to move outward, so that the copper wire 70 always remains taut. This elastic tensioning structure can automatically compensate for the tension changes of the copper wire 70 in real time during the winding process, ensuring that each turn of the coil is in a non-slack state and ensuring the tightness of the copper wire 70 on the winding teeth 21. At the same time, the guide groove on the guide wheel can accurately position the copper wire 70 and prevent the copper wire 70 from deviating during the tensioning process.

[0031] To address the technical shortcomings of existing passive spring tensioning mechanisms, such as lag in tension response, uneven tension abruptly upon the copper wire entering the winding groove, and poor tension consistency throughout the entire process, this embodiment makes the following innovative improvements to the tensioning component 60: a constant tension control system with real-time detection, active adjustment, and closed-loop feedback is constructed, completely solving the industry-wide common problem of inconsistent tension of the copper wire before and after entering the winding groove. Specifically: A miniature linear servo motor is bolted to the end of the outer cylinder 61 away from the gear ring 45. The output shaft of the miniature linear servo motor faces the gear ring 45 and is coaxially fixedly connected to an adjustable spring seat. The outer wall of the adjustable spring seat slides against the inner wall of the outer cylinder. The end face of the adjustable spring seat near the gear ring is fixedly connected to the support spring 63. The outer wall of the inner rod 62 slides against the inner wall of the outer cylinder 61 via a guide key. Pin mounting holes are symmetrically opened on both sides of the mounting bracket 64. A strain gauge force measuring pin is interference-fitted into the pin mounting hole. The lower guide wheel 65 is rotatably mounted in the middle of the strain gauge force measuring pin via a bearing. The upper guide wheel 66 is rotatably mounted via a pin. The device is mounted on the upper part of the mounting bracket 64 and located directly above the lower guide wheel 65. Both the lower guide wheel 65 and the upper guide wheel 66 have semi-circular guide grooves on their circumferential surfaces that match the outer diameter of the copper wire 70. The depth of the guide groove is 1 / 2 of the outer diameter of the copper wire 70, and the inner wall is coated with a polytetrafluoroethylene wear-resistant coating. The copper wire 70 passes through the guide groove between the lower guide wheel 65 and the upper guide wheel 66, and then passes through the ceramic wire hole on the wire tube 46 that matches the copper wire 70 before being wound onto the winding tooth 21. The signal output end of the strain gauge force measuring pin is connected to the main controller of the device through a high-temperature shielded cable. The signal output end of the main controller is electrically connected to the drive end of the micro linear servo motor.

[0032] In actual use, the strain gauge pin can detect the radial pressure of the copper wire 70 acting on the lower guide wheel 65 in real time, and convert the pressure signal into an electrical signal and transmit it to the main controller. The main controller converts the pressure signal into the actual tension value of the copper wire 70 according to the preset calibration curve. When the copper wire 70 transitions from the guide part 51 of the protective plate 50 to the arc-shaped guide part 34 and is about to enter the winding groove, the wire length of the copper wire 70 will change instantaneously, causing the tension to drop instantly. At this time, the strain gauge pin detects that the tension value is lower than the preset standard tension value. The main controller immediately sends a control signal to the micro linear servo motor to drive the adjustable spring seat to move away from the toothed ring 45, compressing the support spring 63 to increase the spring preload. The force pushes the inner rod 62 outward, quickly tightening the copper wire 70. Conversely, when the copper wire 70 exits the winding groove and transitions to the arc-shaped guide part 34, the tension increases instantaneously. The strain gauge force measuring pin detects that the tension value is higher than the preset value. The main controller controls the micro linear servo motor to drive the adjustable spring seat to move closer to the toothed ring 45, releasing the compression of the support spring 63, reducing the spring preload, and causing the inner rod 62 to retract inward, reducing the tension of the copper wire 70. Through the above-mentioned closed-loop control process of real-time detection and active adjustment, the tension fluctuation of the copper wire 70 can be controlled within ±0.05N, ensuring that the tension of the copper wire 70 is completely consistent throughout the entire cycle, including before entering the winding groove, during the process of entering the winding groove, and after the winding is completed.

[0033] Compared to existing purely passive spring tensioning mechanisms, this embodiment achieves non-contact, high-precision real-time tension detection through a strain gauge force-measuring pin, with a detection response time of less than 5ms. This allows for precise capture of minute tension changes the instant the copper wire enters the slot. Furthermore, a micro linear servo motor drives an adjustable spring seat to adjust the preload of the support spring 63. This retains the buffering and shock-absorbing function of the original spring structure while achieving active and continuous tension adjustment with an accuracy of 0.01mm. This completely solves the problem of uneven tension caused by the linear change of spring tension with compression in traditional springs. Closed-loop constant tension control ensures that each turn of the coil has the same tension, resulting in a more neat and compact coil arrangement and an increase in coil fill factor of over 8%. It also effectively avoids problems such as copper wire stretching deformation and insulation layer damage caused by excessive tension, as well as coil loosening and inaccurate turn count caused by insufficient tension. This increases the stator core winding yield from 92% to over 99.5%.

[0034] As a further preferred embodiment, the main controller pre-stores a tension compensation curve corresponding to the rotation angle position of the rotating ring 44. This curve is obtained by pre-calibrating the change in the length of the copper wire 70 at different winding positions. When the rotating ring 44 rotates to the preset angle where the copper wire 70 is about to enter the winding groove, the main controller will send a pre-adjustment signal to the micro linear servo motor in advance, so that the preload of the support spring 63 is adjusted to the corresponding value in advance, thereby further shortening the response time of tension adjustment and completely eliminating the tension fluctuation at the moment the copper wire enters the groove. At the same time, an observation groove extending axially is provided on the outer wall of the outer cylinder 61. The edge of the observation groove is provided with scale lines. An indicator needle is fixed on the outer wall of the inner rod 62. The indicator needle extends through the observation groove to the outside of the outer cylinder 61, which makes it convenient for the operator to intuitively observe the extension and retraction position of the inner rod 62 and the compression of the support spring 63, which facilitates the debugging and maintenance of the equipment.

[0035] In summary, in actual use, the stator core 20 to be wound is first mounted on the three sets of positioning posts 4 on the top of the turntable 3 to complete the positioning and installation of the stator core 20. Then, the electric telescopic rod 31 is activated to drive the mounting base 32 to move towards the stator core 20, so that the engaging groove on the limiting seat 37 is tightly fitted with the outer end of the first winding tooth 21 to be wound, providing radial support for the winding tooth 21. The electric telescopic rod 31 drives the mounting base 32 to move continuously until the arc-shaped guide part 34 at the end of the support plate 33 is aligned with the root of the winding tooth 21. During this process, the pressure spring 38 remains compressed throughout. Then, the copper wire 70 is passed sequentially through the guide groove between the lower guide wheel 65 and the upper guide wheel 66 of the tensioning assembly 60, and then through the conductor. The wire threading hole on the cylinder 46 is used to fix the end of the copper wire 70 to the root of the winding tooth 21. Then, the drive motor 42 is started, and through the meshing transmission of the main gear 43 and the gear ring 45, the rotating ring 44 is driven to rotate around the axis of the electric telescopic rod 31, which drives the two wire cylinders 46 to make synchronous circular motion. Under the guidance of the drainage part 51 on the protective plate 50, the copper wire 70 can smoothly and smoothly enter the winding groove. After being guided by the arc-shaped guide part 34 on the support plate 33, the copper wire 70 can be smoothly and completely wound on the winding tooth 21. During this process, the support spring 63 of the tensioning component 60 will automatically extend and retract according to the tension change of the copper wire 70, and always keep the copper wire 70 in a taut state.

[0036] After the first winding tooth 21 is wound, the drive motor 42 stops rotating, the electric telescopic rod 31 retracts, causing the limit seat 37 to disengage from the winding tooth 21. Then, the servo motor 2 starts, driving the turntable 3 to rotate at a set angle, aligning the next winding tooth 21 to be wound with the top holding assembly 30 and the winding assembly 40. This process is repeated until all winding teeth 21 are wound. Through this collaborative structural design, the present invention achieves automated, high-precision winding of the motor stator core.

[0037] Compared to conventional iron core winding equipment with separate layout, fixed tension adjustment, and no flexible tooth protection in existing technologies, this embodiment breaks through the traditional design concept. It adopts a coaxial integrated layout of the top holding mechanism and the winding mechanism, coupled with a flexible and adaptive top holding and positioning structure at the end of the winding teeth. At the same time, it innovatively sets up a follow-up tensioning component that moves synchronously with the winding trajectory. Combined with a multi-level arc-shaped streamline guide and a zoned anti-cross-wire protection structure, it constructs a fully automatic winding system that integrates iron core deformation protection, constant tension winding, precise indexing and repositioning, and insulation layer protection. It effectively overcomes many long-standing technical drawbacks in the industry, such as large winding tension fluctuations, messy coil arrangement, easy deformation of stator teeth, and easy damage to enameled wire. The winding accuracy, product yield, and equipment automation level are all significantly improved.

[0038] This embodiment discloses a method for using a motor core winding device, which is implemented using the motor core winding device described above. The steps of the method are as follows: S1: The stator core 20 to be wound is mounted on the three sets of positioning posts 4 on the top of the turntable 3 of the support assembly 10, and radial positioning is achieved by the cooperation of the three sets of positioning posts 4 with the center hole of the stator core 20. S2: Activate the electric telescopic rod 31 of the top holding assembly 30, drive the mounting base 32 to move towards the stator core 20, so that the engaging groove on the limit seat 37 is tightly fitted with the outer end of the first winding tooth 21 to be wound, the pressure spring 38 is compressed and provides a continuous elastic holding force, and at the same time, the arc-shaped guide part 34 at the end of the support plate 33 is aligned with the root of the winding tooth 21. S3: Pass the copper wire 70 through the guide groove between the lower guide wheel 65 and the upper guide wheel 66 of the tensioning assembly 60 in sequence, and then through the wire hole on the wire tube 46 of the winding assembly 40, and fix the end of the copper wire 70 to the root of the first winding tooth 21 to be wound. S4: Start the drive motor 42, and drive the rotating ring 44 to rotate at a constant speed around the axis of the electric telescopic rod 31 through the meshing transmission of the main gear 43 and the gear ring 45. This drives the two wire cylinders 46 to make circular motion synchronously. The copper wire 70 smoothly enters the winding groove under the continuous guidance of the guide part 51 of the protective plate 50 and the arc-shaped guide part 34 of the support plate 33. At the same time, the tensioning component 60 rotates synchronously with the rotating ring 44. The elastic extension and contraction of the support spring 63 compensates for the tension change of the copper wire 70 in real time, so that the copper wire 70 maintains a constant tension state throughout the process and is evenly wound on the winding teeth 21. S5: When the first winding tooth 21 is wound, the drive motor 42 stops rotating, the electric telescopic rod 31 retracts and drives the limit seat 37 to disengage from the winding tooth 21, and the servo motor 2 starts to drive the turntable 3 to rotate at a preset indexing angle so that the protective plate of the next winding tooth 21 to be wound is accurately aligned with the top holding assembly 30 and the winding assembly 40. S6: Cyclic winding, repeat steps S2 to S5 until all winding teeth 21 on the stator core 20 have completed the winding operation.

[0039] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A winding device for an electric motor core, comprising a support assembly (10), wherein a stator core (20) is positioned and mounted on the support assembly (10), characterized in that: The stator core (20) is fixedly fitted with a top support assembly (30) on its outer circumference, and the top support assembly (30) is fitted with a winding assembly (40) that is fixed in position relative to the stator core (20). The stator core (20) is uniformly provided with integrally formed winding teeth (21) in the circumferential direction. A winding groove is provided between two adjacent sets of winding teeth (21), and the outer edge of the stator core (20) is matched with protective plates (50) symmetrically arranged on the front and rear sides of the top support assembly (30). The winding assembly (40) includes a wire cylinder (46) that rotates circumferentially around the axis of the top holding assembly (30), and a tensioning assembly (60) corresponding to the wire cylinder (46) is symmetrically fixed on the winding assembly (40). The copper wire (70) passes through the tensioning assembly (60) and the wire cylinder (46) and is wound and assembled on the winding teeth (21) based on the guidance of the protective plate (50) and the top holding assembly (30). The tensioning assembly (60) keeps the copper wire (70) in a tensioned state at all times.

2. The motor core winding device according to claim 1, characterized in that: The support assembly (10) includes a fixed base (1), a servo motor (2) is fixed at the bottom center of the fixed base (1), the output end of the servo motor (2) passes through the fixed base (1) and a turntable (3) is fixedly installed thereon, three sets of positioning columns (4) are fixed on the top of the turntable (3) along the circumferential direction, and the stator core (20) is positioned on the three sets of positioning columns (4), and a bearing ring (5) for supporting the turntable (3) is fixed on the top of the fixed base (1).

3. The motor core winding device according to claim 1, characterized in that: The top support assembly (30) includes an electric telescopic rod (31) fixedly installed by a bracket. The output end of the electric telescopic rod (31) is fixedly installed with a mounting base (32). A base plate (35) is fixedly installed at the middle position on the side of the mounting base (32) near the stator core (20). A guide seat (36) is slidably fitted on the outer side of the base plate (35). A pressure spring (38) fixedly connected to the end of the base plate (35) is fixed inside the guide seat (36). A limit seat (37) is fixed at the outer end of the guide seat (36). Support plates (33) are symmetrically installed on the top and bottom of the side of the mounting base (32) near the stator core (20). Each set of support plates (33) has an arc-shaped guide portion (34) integrally formed at the end facing the stator core (20).

4. The motor core winding device according to claim 3, characterized in that: The limiting seat (37) and the winding tooth (21) are directly opposite each other, and the outer side wall of the limiting seat (37) is provided with a locking groove that fits with the outer end of the winding tooth (21). The sliding stroke of the guide seat (36) on the substrate (35) matches the length of the winding tooth (21). The protective plate (50) is fixedly installed by the bracket to fix its position, and the protective plate (50) is located on the outside of the winding tooth (21). Each set of protective plates (50) has an integrally formed drainage part (51) at the end near the limiting seat (37), and the outer wall of the drainage part (51) is set as an arc-shaped surface facing the winding groove.

5. The motor core winding device according to claim 4, characterized in that: The distance between the two sets of support plates (33) is slightly greater than the height of the winding teeth (21), and the outer wall of each set of arc-shaped guides (34) is arc-shaped, and the guide tube (46) and the arc-shaped guides (34) correspond to each other.

6. The motor core winding device according to claim 4, characterized in that: The winding assembly (40) also includes a fixed ring (41) and a rotating ring (44) movably sleeved on the outside of the output end of the electric telescopic rod (31). The fixed ring (41) and the rotating ring (44) are fixedly connected by a bracket so that their positions are fixed relative to the stator core (20). A drive motor (42) is fixed on the top of the fixed ring (41). A main gear (43) is fixed on the output end of the drive motor (42). A toothed ring (45) that meshes with the main gear (43) is fixed on the end face of the rotating ring (44). The wire tube (46) is symmetrically fixed on the upper and lower sides of the outer edge sidewall of the rotating ring (44).

7. The motor core winding device according to claim 6, characterized in that: The tensioning assembly (60) includes an outer cylinder (61) fixed on the outer sidewall of the toothed ring (45), an inner rod (62) is guided and assembled inside the outer cylinder (61), the inner end of the inner rod (62) extends into the inner cylinder (61) and is fixedly connected to a support spring (63), and the other end of the support spring (63) is fixed on the inner sidewall of the outer cylinder (61), the outer end of the inner rod (62) extends out of the outer cylinder (61) and is fixedly mounted on a mounting bracket (64), and a lower guide wheel (65) and an upper guide wheel (66) are rotatably mounted on the mounting bracket (64) via a pin.

8. The motor core winding device according to claim 7, characterized in that: A miniature linear servo motor is fixedly installed at the end of the outer cylinder (61) away from the gear ring (45) by bolts. The output shaft of the miniature linear servo motor is oriented towards the gear ring (45) and is coaxially fixedly connected to an adjustable spring seat. The outer wall of the adjustable spring seat is slidably engaged with the inner wall of the outer cylinder. The end face of the adjustable spring seat near the gear ring is fixedly connected to the support spring (63). The outer wall of the inner rod (62) is slidably engaged with the inner wall of the outer cylinder (61) by a guide key. Pin mounting holes are symmetrically opened on both sides of the mounting bracket (64). A strain gauge force measuring pin is installed in the pin mounting hole with an interference fit. The lower guide wheel (65) is rotated by a bearing. The upper guide wheel (66) is mounted on the upper part of the mounting bracket (64) and located directly above the lower guide wheel (65) via the pin shaft. The lower guide wheel (65) and the upper guide wheel (66) are both provided with semi-circular guide grooves that match the outer diameter of the copper wire (70). The depth of the guide groove is 1 / 2 of the outer diameter of the copper wire (70) and the inner wall is coated with a polytetrafluoroethylene wear-resistant coating. The copper wire (70) passes through the guide groove between the lower guide wheel (65) and the upper guide wheel (66) and passes through the wire cylinder (46) and is wound on the winding tooth (21). The wire cylinder (46) is provided with a wire hole that matches the copper wire (70).

9. A method of using a motor core winding device, implemented using the motor core winding device as described in any one of claims 1-8, characterized in that: The steps for using this method are as follows: S1: The stator core (20) to be wound is mounted on the three sets of positioning posts (4) on the top of the turntable (3) of the support assembly (10), and radial positioning is achieved by the cooperation of the three sets of positioning posts (4) with the center hole of the stator core (20). S2: Activate the electric telescopic rod (31) of the top holding assembly (30) to drive the mounting base (32) to move towards the stator core (20), so that the engagement groove on the limit seat (37) is tightly fitted with the outer end of the first winding tooth (21) to be wound, the pressure spring (38) is compressed and provides a continuous elastic holding force, and at the same time, the arc-shaped guide (34) at the end of the support plate (33) is aligned with the root of the winding tooth (21); S3: Pass the copper wire (70) through the guide groove between the lower guide wheel (65) and the upper guide wheel (66) of the tensioning assembly (60) in sequence, and then through the wire hole on the wire tube (46) of the winding assembly (40) to fix the end of the copper wire (70) at the root of the first winding tooth (21) to be wound. S4: Start the drive motor (42), and drive the rotating ring (44) to rotate at a constant speed around the axis of the electric telescopic rod (31) through the meshing transmission of the main gear (43) and the gear ring (45). This drives the two wire cylinders (46) to make circular motion synchronously. The copper wire (70) smoothly enters the winding groove under the continuous guidance of the guide part (51) of the protective plate (50) and the arc-shaped guide part (34) of the support plate (33). At the same time, the tensioning component (60) rotates synchronously with the rotating ring (44). The elastic extension and contraction of the support spring (63) compensates for the tension change of the copper wire (70) in real time, so that the copper wire (70) maintains a constant tension state throughout the process and is evenly wound on the winding teeth (21). S5: When the first winding tooth (21) is wound, the drive motor (42) stops rotating, the electric telescopic rod (31) retracts and drives the limit seat (37) to disengage from the winding tooth (21), the servo motor (2) is started to drive the turntable (3) to rotate at a preset indexing angle so that the next winding tooth (21) to be wound is accurately aligned with the top holding assembly (30) and the winding assembly (40). S6: Repeat steps S2 to S5 until all winding teeth (21) on the stator core (20) have completed the winding operation.

Images