Lead forming device and lead forming method for PFC inductor processing

Abstract

A kind of PFC inductance processing lead forming device and lead forming method, it is related to inductance processing equipment technical field.The device includes machine body and be located on its pull line mechanism and torsion line mechanism, machine body is equipped with pull line station.Pull line mechanism includes pull line sliding seat, pull line clamp, pull line cylinder and pull line drive module.Pull line cylinder drives pull line clamp to close to hold shorter first pin of semi-finished inductance, pull line drive module drives pull line sliding seat to be away from pull line station, first pin is stretched to be consistent with the length of second pin.Torsion line mechanism includes first torsion line component and second torsion line component, first torsion line component applies torsion around its own axis to two pins, and second torsion line component bends two pins from inclined state to vertical state.Adopt the above scheme, it can solve the problem that manual pull line is difficult to guarantee the consistency of pin length, the inconsistent force and angle of manual torsion line lead to uneven product quality, and the problem of low production efficiency.

Description

Technical Field

[0001] This invention relates to the field of inductor processing equipment technology, specifically to a lead forming device and method for PFC inductor processing. Background Technology

[0002] PFC inductors are key magnetic components in power electronic systems, widely used in switching power supplies, variable frequency air conditioners, and new energy vehicle charging piles. In the production process of PFC inductors, the semi-finished inductors after winding need to have their leads shaped, which usually includes two processes: wire drawing and wire twisting, to make the leads meet the shape requirements for subsequent assembly or welding.

[0003] Currently, when winding PFC inductors, the starting wire is shorter to allow it to wind around the magnetic ring, while the ending wire can be longer. Therefore, the semi-finished inductor naturally has one short lead and one long lead. During subsequent processing, the shorter lead needs to be lengthened to a length comparable to the longer lead, and then both leads are twisted into their final shapes.

[0004] In existing technologies, the aforementioned wire pulling and twisting operations are mostly performed manually. Operators need to manually fix the inductor, first using pliers to lengthen the short leads, and then twisting the leads at both ends separately. However, manual wire pulling makes it difficult to precisely control the lengthening of the leads, resulting in inconsistent lead lengths and affecting subsequent assembly. During manual twisting, the twisting force and angle vary from person to person, easily causing unequal twist counts and deviations in the twist shape, thus affecting the reliability of welding or electrical connections. Furthermore, manual operation requires multiple clamping and repositioning operations, resulting in high labor intensity and low production efficiency, making it difficult to meet the needs of mass production. Summary of the Invention

[0005] The purpose of this application is to provide a lead forming device and a lead forming method for PFC inductor processing, so as to solve the problems in the prior art that it is difficult to ensure the consistent pin length when manually pulling wires, and that inconsistent twisting force and angle during manual twisting lead to inconsistent product quality and low production efficiency.

[0006] The present invention provides a lead forming device for PFC inductor processing. The technical solution adopted is: a lead forming device for PFC inductor processing, characterized in that it includes a body and a wire pulling mechanism and a wire twisting mechanism provided on the body, wherein the body is provided with a wire pulling station. The wire pulling mechanism is located at the wire pulling station and includes a wire pulling slide seat slidably mounted on the machine body, a wire pulling clamp mounted on the wire pulling slide seat, a wire pulling cylinder for driving the wire pulling clamp to open and close, and a wire pulling drive module for driving the wire pulling slide seat to move toward or away from the wire pulling station. The wire pulling cylinder drives the wire pulling clamp to close to clamp the first pin of the semi-finished inductor, and the wire pulling drive module drives the wire pulling slide seat to move away from the wire pulling station to stretch the first pin to the same length as the second pin. The twisting mechanism includes a first twisting component and a second twisting component. The first twisting component is used to apply a twist around the axis of the first and second pins of the semi-finished inductor. The second twisting component is used to bend the first and second pins of the semi-finished inductor from an inclined state relative to the semi-finished inductor downwards to a vertical state.

[0007] Optionally, the first twisted wire assembly includes a first twisted wire support for carrying a semi-finished inductor, two first twisted wire fixing seats symmetrically arranged on both sides of the first twisted wire support, a first twisted wire sliding seat slidably arranged on the first twisted wire fixing seat, a first twisted wire clamping jaw arranged on the first twisted wire sliding seat, a first twisted wire sliding cylinder for driving the first twisted wire sliding seat to move towards or away from the first twisted wire support, a first clamping jaw cylinder for driving the first twisted wire clamping jaw to open and close, and a first twisted wire rotating cylinder for driving the first twisted wire clamping jaw to rotate. The first twisted wire support is provided with a first support groove for carrying the semi-finished inductor.

[0008] Optionally, the first twisting assembly further includes a first twisting fixing frame, a first twisting rotary motor disposed on the first twisting fixing frame, and a clamping component disposed on the first twisting support. The first twisting support is rotatably disposed on the first twisting fixing frame. The first twisting rotary motor is used to drive the first twisting support to rotate, so that the first twisting jaws can smoothly clamp the first pin and the second pin of the semi-finished inductor. The clamping component is used to clamp the semi-finished inductor into the first support groove.

[0009] Optionally, the second twisting assembly includes a second twisting bracket, a second twisting support fixed on the second twisting bracket, two symmetrically arranged second twisting slide seats that can slide towards or away from the second twisting support seats, a second twisting gripper on the second twisting slide seats, a second twisting slide cylinder for driving the second twisting slide seats to move towards or away from the second twisting support seats, a second gripper cylinder for driving the second twisting gripper to open and close, and a second twisting rotation cylinder for driving the second twisting gripper to rotate. The second twisting support seat has a second support groove for carrying the semi-finished inductor. The second twisting rotation cylinder is fixed on the second twisting slide seat. A mounting plate is fixedly provided on the output end of the second twisting rotation cylinder. The second gripper cylinder is fixedly mounted on the mounting plate, and the output ends of the second gripper cylinder and the second twisting rotation cylinder are offset.

[0010] Optionally, the lead forming device for PFC inductor processing provided by the present invention further includes an inductor positioning and conveying mechanism. The machine body is provided with a feeding station. The inductor positioning and conveying mechanism includes a sliding frame slidably disposed between the feeding station and the wire drawing station, a positioning seat disposed on the sliding frame, a positioning component disposed on the positioning seat, and an inductor conveying module for driving the sliding frame to move back and forth between the feeding station and the wire drawing station. The positioning seat is provided with a positioning groove for positioning the semi-finished inductor. One side of the positioning groove is open. The positioning component is located on one side of the opening of the positioning groove and is used to press the semi-finished inductor against the positioning groove.

[0011] Optionally, the inductive positioning and conveying mechanism further includes a rotating seat, a rotating assembly, and a top wire assembly. The rotating seat is rotatably connected to the sliding frame, the positioning seat is fixedly mounted on the rotating seat, the rotating assembly is mounted on the sliding frame to drive the rotating seat to rotate relative to the sliding frame, and the top wire assembly is mounted on the rotating seat to lift the first pin to a height that cooperates with the wire pulling mechanism.

[0012] Optionally, the rotating assembly includes a rotating seat fixedly mounted on a sliding frame and an inductive positioning rotary motor. The rotating seat is fixedly mounted on the rotating seat, and the output shaft of the inductive positioning rotary motor is fixedly connected to the rotating seat to drive the rotating seat to rotate relative to the sliding frame.

[0013] Optionally, the top wire assembly includes a top wire block slidably disposed on the positioning seat and a top wire cylinder for driving the top wire block to move toward or away from the positioning groove. The top wire block is inclined relative to the positioning seat, and the inclination angle of the top wire block is consistent with the initial inclination angle of the first pin. A guide surface is provided on the side of the top wire block facing the positioning groove. The guide surface is used to contact the first pin and lift the first pin when the top wire block moves toward the positioning groove.

[0014] Optionally, the lead forming device for PFC inductor processing provided by the present invention further includes a transfer mechanism and a feeding mechanism. The twisting mechanism is located on one side of the inductor positioning and conveying mechanism, and the feeding mechanism is located on the side of the twisting mechanism away from the inductor positioning and conveying mechanism. The transfer mechanism spans the inductor positioning and conveying mechanism, the twisting mechanism, and the feeding mechanism, and is used to transfer the semi-finished inductor after stretching on the inductor positioning and conveying mechanism to the twisting mechanism, and to convey the twisted semi-finished inductor to the feeding mechanism for feeding.

[0015] This application also provides a lead forming method for a PFC inductor, which is based on the lead forming apparatus for PFC inductor processing described above, and includes the following steps: Place the semi-finished inductor at the wire drawing station; The cable clamp is closed by driving the cable pull cylinder to clamp the first pin of the semi-finished inductor, which is shorter in length. The wire drawing drive module drives the wire drawing slide to move away from the wire drawing station, stretching the first pin to the same length as the second pin. The first twisting assembly applies a twist around the axis of the first and second pins of the semi-finished inductor that has been drawn into a wire. The second twisting assembly bends the first and second leads of the semi-finished inductor from an inclined state relative to the semi-finished inductor downwards to a vertical state.

[0016] After adopting the above technical solution, the beneficial effects of the present invention are as follows: This application provides a lead forming device and method for PFC inductor processing. During operation, a wire-pulling cylinder drives a wire-pulling clamp to close and hold the shorter first pin. Then, a wire-pulling drive module drives a wire-pulling slide to move away from the wire-pulling station, stretching the first pin to the same length as the second pin. This automatically compensates for the length difference between the two pins, avoiding subsequent forming defects caused by uneven pin lengths in the incoming material. Subsequently, a first twisting assembly applies a twist around the pin's own axis to the first and second pins of the semi-finished inductor. A second twisting assembly then bends the first and second pins from an inclined state relative to the semi-finished inductor downwards to a vertical state, achieving precise lead forming from inclined to vertical. Throughout the process, wire pulling, twisting, and bending are completed automatically without manual intervention, improving lead forming efficiency and ensuring pin length consistency and bending angle accuracy, thereby increasing the yield rate and automation level of PFC inductor lead forming. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the overall structure of this embodiment; Figure 2 yes Figure 1 A view showing the device after the transfer mechanism has been removed; Figure 3 These are illustrations of the semi-finished inductor in this embodiment before processing, after lead stretching, and after wire twisting. Figure 4 This is a diagram illustrating the wire-pulling mechanism in this embodiment; Figure 5 This is a diagram illustrating the first twisted wire assembly in this embodiment; Figure 6 yes Figure 5 A diagram showing the product after removing the semi-finished inductor and some structural components; Figure 7 This is a diagram illustrating the second twisted wire assembly in this embodiment; Figure 8 This is a diagram illustrating the inductive positioning and conveying mechanism in this embodiment; Figure 9 yes Figure 8 A display image after removing the semi-finished inductor; Figure 10 This is a diagram illustrating the transfer mechanism in this embodiment; Figure 11 This is a flowchart of a lead forming method for a PFC inductor provided in this embodiment.

[0019] Explanation of reference numerals in the attached drawings: 100, machine body; 101, wire pulling station; 102, first twisting station; 103, second twisting station; 104, loading station; 105, unloading station; 10, wire pulling mechanism; 11, wire pulling sliding seat; 12, wire pulling clamp; 13, wire pulling cylinder; 14, wire pulling drive module; 20. Twisting mechanism; 21. First twisting assembly; 210. First twisting support; 2101. First support groove; 211. First twisting fixing seat; 212. First twisting sliding seat; 213. First twisting gripper; 214. First twisting sliding cylinder; 215. First gripper cylinder; 216. First twisting rotary cylinder; 217. First twisting fixing frame; 218. First twisting rotary motor; 219. Clamping assembly; 2191. Clamping block; 2192. Clamping cylinder; 22. Second twisting assembly; 221. Second twisting fixing frame; 222. Second twisting support; 2221. Second support groove; 223. Second twisting sliding seat; 224. Second twisting gripper; 225. Second twisting sliding cylinder; 226. Second gripper cylinder; 227. Second twisting rotary cylinder; 228. Mounting plate; 30. Inductive positioning and conveying mechanism; 31. Sliding frame; 32. Positioning seat; 321. Positioning groove; 33. Positioning assembly; 331. Positioning block; 332. Positioning cylinder; 34. Inductive conveying module; 35. Rotating seat; 36. Rotating assembly; 361. Rotating seat; 362. Inductive positioning rotary motor; 37. Top wire assembly; 371. Top wire block; 372. Top wire cylinder; 40. Transfer mechanism; 41. Transfer fixture; 42. First transfer robot; 43. Second transfer robot; 44. Third transfer robot; 50. Feeding mechanism; 51. Feeding conveyor belt; 52. Carrier; 53. Feeding conveyor module; 200, Semi-finished inductor; 201, First pin; 202, Second pin. Detailed Implementation

[0020] The following will refer to the appendices in the embodiments of the present invention. Figures 1-11 The technical solutions in the embodiments of the present invention are clearly and completely described herein. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0021] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0022] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, if the word "and / or" appears throughout the text, it means including three parallel solutions; for example, "A and / or B" includes solution A, solution B, or a solution that simultaneously satisfies A and B. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0023] This embodiment provides a lead forming apparatus for PFC inductor processing, referencing... Figures 1-11 It includes a machine body 100 and a wire pulling mechanism 10 and a wire twisting mechanism 20 provided on the machine body 100. A wire pulling station 101 is provided on the machine body 100. The wire pulling mechanism 10 is located at the wire pulling station 101 and includes a wire pulling slide seat 11 slidably mounted on the machine body 100, a wire pulling clamp 12 mounted on the wire pulling slide seat 11, a wire pulling cylinder 13 for driving the wire pulling clamp 12 to open and close, and a wire pulling drive module 14 for driving the wire pulling slide seat 11 to move toward or away from the wire pulling station 101. The wire pulling cylinder 13 drives the wire pulling clamp 12 to close and clamp the first pin 201 of the semi-finished inductor 200. The wire pulling drive module 14 drives the wire pulling slide seat 11 to move away from the wire pulling station 101 to stretch the first pin 201 to the same length as the second pin 202. The wire twisting mechanism 20 includes a first wire twisting assembly 21 and a second wire twisting assembly 22. The first wire twisting assembly 21 is used to apply a twist about the axis of the first pin 201 and the second pin 202 of the semi-finished inductor 200. The second wire twisting assembly 22 is used to bend the first pin 201 and the second pin 202 of the semi-finished inductor 200 from an inclined state relative to the semi-finished inductor 200 downward to a vertical state.

[0024] It should be noted that since the semi-finished inductor 200 after winding will naturally form a state where one end has a short lead and the other end has a long lead, in order to facilitate the distinction between the short lead and the long lead, in this embodiment the short lead is named the first lead 201 and the long lead is named the second lead 202.

[0025] Understandably, during operation, the wire-pulling cylinder 13 drives the wire-pulling clamp 12 to close and hold the shorter first pin 201. Then, the wire-pulling drive module 14 drives the wire-pulling slide 11 to move away from the wire-pulling station 101, stretching the first pin 201 to the same length as the second pin 202. This automatically compensates for the length difference between the two pins, avoiding subsequent molding defects caused by uneven pin lengths in the incoming material. Subsequently, the first twisting assembly 21 applies a twist around the pin's own axis to the first pin 201 and the second pin 202 of the semi-finished inductor 200. Then, the second twisting assembly 22 bends the first pin 201 and the second pin 202 from an inclined state relative to the semi-finished inductor 200 downwards to a vertical state, achieving precise molding of the lead wire from inclined to vertical. Throughout the process, the wire pulling, twisting, and bending are completed automatically in sequence without manual intervention. This improves the efficiency of lead forming and ensures the consistency of pin length and the accuracy of bending angle, thereby increasing the yield rate and automation level of PFC inductor lead forming.

[0026] Furthermore, the first twisted wire assembly 21 includes a first twisted wire support 210 for carrying the semi-finished inductor 200, two first twisted wire fixing seats 211 symmetrically arranged on both sides of the first twisted wire support 210, a first twisted wire sliding seat 212 slidably arranged on the first twisted wire fixing seat 211, a first twisted wire gripper 213 arranged on the first twisted wire sliding seat 212, a first twisted wire sliding cylinder 214 for driving the first twisted wire sliding seat 212 to move towards or away from the first twisted wire support 210, a first gripper cylinder 215 for driving the first twisted wire gripper 213 to open and close, and a first twisted wire rotating cylinder 216 for driving the first twisted wire gripper 213 to rotate. The first twisted wire support 210 is provided with a first support groove 2101 for carrying the semi-finished inductor 200.

[0027] In this embodiment, the machine body 100 is also provided with a first twisting station 102 and a second twisting station 103, and a first twisting assembly 21 and a second twisting assembly 22 are respectively provided at the first twisting station 102 and the second twisting station 103. When the wire pulling mechanism 10 stretches the first pin 201 of the semi-finished inductor 200 to the same length as the second pin 202, the semi-finished inductor 200 is placed in the first bearing groove 2101 on the first twisting bearing seat 210. The two first twisting sliding cylinders 214 drive the left and right first twisting sliding seats 212 to move towards the middle synchronously, so that the first gripper cylinder 215 drives the two first twisting grippers 213 to close and clamp the first pin 201 and the second pin 202 respectively. Then the first twisting rotating cylinder 216 drives the grippers to rotate a preset number of times, for example, the first pin 201 rotates clockwise once and the second pin 202 rotates counterclockwise once. After rotation is completed, the first gripper cylinder 215 drives the first twisting gripper 213 to open, and at the same time, the two first twisting sliding cylinders 214 drive the first twisting sliding seat 212 to move away from the first twisting bearing seat 210, completing the reset and preparing for the next twisting.

[0028] Furthermore, the first twisting assembly 21 also includes a first twisting fixing frame 217, a first twisting rotary motor 218 disposed on the first twisting fixing frame 217, and a clamping assembly 219 disposed on the first twisting support 210. The first twisting support 210 is rotatably disposed on the first twisting fixing frame 217. The first twisting rotary motor 218 is used to drive the first twisting support 210 to rotate, so that the first twisting claw 213 can smoothly clamp the first pin 201 and the second pin 202 of the semi-finished inductor 200. The clamping assembly 219 is used to clamp the semi-finished inductor 200 against the first support groove 2101.

[0029] Understandably, when the semi-finished inductor 200 is placed in the first bearing groove 2101, there may be a deviation between its first pin 201 and second pin 202 due to the placement angle. If directly clamped, the two first twisting jaws 213 may not be able to clamp the first pin 201 and the second pin 202 simultaneously. Therefore, the first twisting bearing seat 210 is driven by the first twisting rotary motor 218 to adjust the angle, so that the two first twisting jaws 213 can smoothly clamp the first pin 201 and the second pin 202, thereby avoiding clamping failure caused by excessive or asymmetrical initial pin tilt angles. At the same time, the clamping component 219 presses the semi-finished inductor 200 against the first bearing groove 2101 to prevent the semi-finished inductor 200 from rotating or shaking during the angle fine-tuning and twisting process, ensuring the quality of the twisting.

[0030] In this embodiment, the clamping assembly 219 includes a clamping block 2191 slidably disposed on the first twisted wire support 210 and a clamping cylinder 2192 for driving the clamping block 2191 to slide. The clamping block 2191 is located on one side of the opening of the first support groove 2101. During operation, the clamping cylinder 2192 drives the clamping block 2191 to move towards the first support groove 2101, thereby clamping the semi-finished inductor 200 against the inner wall of the other side of the first support groove 2101 from one side of the opening of the first support groove 2101, thereby fixing the semi-finished inductor 200, effectively preventing the semi-finished inductor 200 from shifting position during subsequent rotation and twisting, and ensuring twisting accuracy and processing stability.

[0031] Further, the second twisting assembly 22 includes a second twisting bracket 221, a second twisting support 222 fixedly mounted on the second twisting bracket 221, two symmetrically arranged second twisting sliding seats 223 that can slide towards or away from the second twisting support 222, a second twisting gripper 224 mounted on the second twisting sliding seats 223, a second twisting sliding cylinder 225 for driving the second twisting sliding seats 223 to move towards or away from the second twisting support 222, and a second twisting sliding cylinder 225 for driving the second twisting gripper 224 to open and close. The system includes a two-claw cylinder 226 and a second twisting rotary cylinder 227 for driving the second twisting claw 224 to rotate. The second twisting support 222 has a second support groove 2221 for supporting the semi-finished inductor 200. The second twisting rotary cylinder 227 is fixedly mounted on the second twisting sliding seat 223. A mounting plate 228 is fixedly mounted on the output end of the second twisting rotary cylinder 227. The second claw cylinder 226 is fixedly mounted on the mounting plate 228, and the output ends of the second claw cylinder 226 and the second twisting rotary cylinder 227 are offset.

[0032] Understandably, after the semi-finished inductor 200, after being twisted by the first twisting assembly 21, is placed in the second bearing groove 2221 on the second twisting support 222, the second twisting sliding cylinder 225 drives the second twisting sliding seat 223 to move towards the center. Subsequently, the second clamping cylinder 226 drives the second twisting clamping jaw 224 to clamp the first pin 201 and the second pin 202. At this time, the two pins are still in an inclined state extending downwards from the semi-finished inductor 200. Then, the second twisting rotating cylinder 227 is activated, and its output end drives the mounting plate 228 to rotate downwards. Since the second clamping cylinder 226 is mounted on the mounting plate 228 and is offset from the rotation axis of the output end by a certain distance, when the output end rotates downwards, the clamping jaw will draw an arc trajectory around the horizontal axis, thereby bending the pin downwards. By controlling the rotation angle of the rotating cylinder (usually 90°), the inclined pin can be precisely bent to a vertical state. Compared to manual bending with pliers, this application can ensure that the first pin 201 and the second pin 202 have the same height and angle after bending, avoiding the common problems of bending point offset and unequal bending angles in manual bending, and providing accurate pin posture for subsequent processes.

[0033] Furthermore, the lead forming apparatus for PFC inductor processing provided in this application also includes an inductor positioning and conveying mechanism 30. The machine body 100 is provided with a loading station 104. The inductor positioning and conveying mechanism 30 includes a sliding frame 31 slidably disposed between the loading station 104 and the wire pulling station 101, a positioning seat 32 disposed on the sliding frame 31, a positioning component 33 disposed on the positioning seat 32, and an inductor conveying module 34 for driving the sliding frame 31 to move back and forth between the loading station 104 and the wire pulling station 101. The positioning seat 32 is provided with a positioning groove 321 for positioning the semi-finished inductor 200. One side of the positioning groove 321 is open. The positioning component 33 is located on one side of the opening of the positioning groove 321 and is used to press the semi-finished inductor 200 against the positioning groove 321.

[0034] Understandably, by setting a loading station 104 and an inductor positioning and conveying mechanism 30 on the machine body 100, the automatic conveying and precise positioning of the semi-finished inductor 200 from the loading station 104 to the wire drawing station 101 is realized. During operation, the semi-finished inductor 200 is first placed in the positioning groove 321 on the positioning seat 32, and the semi-finished inductor 200 is positioned and fixed by the positioning component 33. Then, the sliding frame 31 is driven by the inductor conveying module 34 to move to the wire drawing station 101, so that the wire drawing mechanism 10 can smoothly perform wire drawing on the semi-finished inductor 200. After the wire drawing is completed, the inductor conveying module 34 drives the sliding frame 31 to move back to the loading station 104.

[0035] Furthermore, the inductive positioning and conveying mechanism 30 also includes a rotating seat 35, a rotating assembly 36, and a top wire assembly 37. The rotating seat 35 is rotatably connected to the sliding frame 31, the positioning seat 32 is fixedly mounted on the rotating seat 35, the rotating assembly 36 is mounted on the sliding frame 31 to drive the rotating seat 35 to rotate relative to the sliding frame 31, and the top wire assembly 37 is mounted on the rotating seat 35 to lift the first pin 201 to a height that cooperates with the wire pulling mechanism 10.

[0036] It should be noted that, because the first pin 201 of the semi-finished inductor 200 after winding is short and hangs down at a certain angle, the wire pulling clamp 12 of the wire pulling mechanism 10 is difficult to clamp directly. Before pulling the wire, the rotating assembly 36 drives the rotating seat 35 to rotate at a certain angle, causing the first pin 201 to rotate. Then, the wire lifting assembly 37 moves to lift the shorter first pin 201 upward to a height that matches the wire pulling clamp 12, thereby ensuring that the wire pulling action can be performed stably.

[0037] Furthermore, the positioning component 33 includes a positioning block 331 slidably mounted on the rotating seat 35 and a positioning cylinder 332 for driving the positioning block 331 to slide. The positioning block 331 is located on one side of the opening of the positioning groove 321. During operation, the positioning cylinder 332 drives the positioning block 331 to move towards the positioning groove 321, thereby pressing the semi-finished inductor 200 against the inner wall of the other side of the positioning groove 321 from one side of the opening of the positioning groove 321. This achieves the positioning and fixing of the semi-finished inductor 200, effectively preventing the semi-finished inductor 200 from shifting position during subsequent rotation, lifting, conveying, and wire drawing processes, ensuring wire drawing accuracy and processing stability.

[0038] The top wire assembly 37 includes a top wire block 371 slidably mounted on the positioning seat 32 and a top wire cylinder 372 for driving the top wire block 371 to move toward or away from the positioning groove 321. The top wire block 371 is inclined relative to the positioning seat 32, and the inclination angle of the top wire block 371 is consistent with the initial inclination angle of the first pin 201. A guide surface is provided on the side of the top wire block 371 facing the positioning groove 321. The guide surface is used to contact and lift the first pin 201 when the top wire block 371 moves toward the positioning groove 321. By inclining the top wire block 371 relative to the positioning seat 32, and with the inclination angle consistent with the initial inclination angle of the first pin 201, the guide surface of the top wire block 371 can smoothly contact the first pin 201 when it moves toward the positioning groove 321, and lift it to the required height along the inclination direction of the pin, avoiding pin bending or damage caused by the inconsistency between the lifting direction and the inclination direction of the pin. This achieved a lossless lifting of the first pin 201, ensuring the integrity of the pin and the accuracy of subsequent stretching.

[0039] Furthermore, the rotating assembly 36 includes a rotating seat 361 fixedly mounted on the sliding frame 31 and an inductive positioning rotary motor 362. The rotating seat 35 is fixedly mounted on the rotating seat 361, and the output shaft of the inductive positioning rotary motor 362 is fixedly connected to the rotating seat 361 to drive the rotating seat 361 to rotate relative to the sliding frame 31. When the semi-finished inductor 200 is placed in the positioning groove 321 and positioned by the positioning assembly 33, the rotating seat 361 is driven to rotate by the inductive positioning rotary motor 362, which in turn drives the positioning seat 32 to rotate, thereby realizing the angle adjustment of the first pin 201 of the semi-finished inductor 200, so that the wire pulling mechanism 10 can smoothly clamp the first pin 201 and perform the stretching operation.

[0040] Furthermore, the lead forming apparatus for PFC inductor processing provided in this application also includes a transfer mechanism 40 and a feeding mechanism 50. A feeding station 105 is provided on the machine body 100. The feeding station 105 is located on the side of the second twisting station 103 away from the first twisting station 102. The twisting mechanism 20 is located on one side of the inductor positioning and conveying mechanism 30. The feeding mechanism 50 is located at the feeding station 105. The transfer mechanism 40 spans the inductor positioning and conveying mechanism 30, the twisting mechanism 20 and the feeding mechanism 50. It is used to transfer the semi-finished inductor 200 after stretching treatment on the inductor positioning and conveying mechanism 30 to the twisting mechanism 20, and to convey the twisted semi-finished inductor 200 to the feeding mechanism 50 for feeding.

[0041] Understandably, by setting up the transfer mechanism 40 and the unloading mechanism 50, the automatic transfer of the semi-finished inductor 200 after stretching to the twisting mechanism 20, and the automatic conveying of the twisted inductor to the unloading mechanism 50 are achieved. The entire transfer process requires no manual intervention, avoiding manual material handling between different workstations, reducing human error and operation time, and improving the automation level and production efficiency of the entire line. At the same time, the unloading mechanism 50 can output the formed finished products in an orderly manner, facilitating the connection with subsequent processes.

[0042] Specifically, the transfer mechanism 40 includes a transfer frame 41 fixedly mounted on the machine body 100, and a first transfer robot 42, a second transfer robot 43, and a third transfer robot 44 slidably mounted on the transfer frame 41. The transfer frame 41 spans the loading station 104, the first twisting station 102, the second twisting station 103, and the unloading station 105. The first transfer robot 42 and the second transfer robot 43 are synchronous robots. The first transfer robot 42 is slidably mounted between the loading station 104 and the first twisting station 102, and the second transfer robot 43 is slidably mounted between the first twisting station 102 and the second twisting station 105. Between positions 103, a third transfer robot 44 is slidably disposed between the second twisting station 103 and the unloading station 105. The first transfer robot 42 is used to transfer the semi-finished inductor 200 at the loading station 104 to the first twisting support 210 on the first twisting station 102. The second transfer robot 43 is used to transfer the semi-finished inductor 200 on the first twisting support 210 to the second twisting support 222 on the second twisting station 103. The third transfer robot 44 is used to transfer the semi-finished inductor 200 that has completed twisting on the second twisting support 222 to the unloading mechanism 50 on the unloading station 105.

[0043] The unloading mechanism 50 includes an unloading conveyor belt 51 located at the unloading station 105, a carrier 52 slidably mounted on the unloading conveyor belt 51, and an unloading conveying module 53 for driving the carrier 52 to move along the unloading conveyor belt 51. The carrier 52 is provided with multiple receiving slots for accommodating semi-finished inductors 200, so as to realize the synchronous conveying of multiple semi-finished inductors 200 with completed lead forming.

[0044] During operation, the first transfer robot 42 first picks up the semi-finished inductor 200 at the loading station 104, then slides along the transfer fixing frame 41 to the first twisting station 102, placing the semi-finished inductor 200 onto the first twisting support 210. The first twisting assembly 21 then applies a twist around the lead's own axis. Simultaneously, the second transfer robot 43 moves the semi-finished inductor 200 from the first twisting station 102 to the second twisting support 222, bending the first lead 201 and second lead 202 of the semi-finished inductor 200 downwards via the second twisting assembly 22. After both twisting processes are completed, the third transfer robot 44 picks up the formed semi-finished inductor 200 and transfers it to the unloading mechanism 50 at the unloading station 105, where the unloading mechanism 50 completes the unloading. The three transfer robots work together to achieve continuous automated processing of PFC inductor lead twisting, effectively improving processing efficiency and reducing the labor intensity of manual operation.

[0045] In this embodiment, the wire drawing drive module 14, the inductive conveying module 34, and the unloading conveying module 53 are all linear drive components such as slide cylinders or linear motors, which can provide stable and controllable linear power output, ensure the positional accuracy of movement between each station, meet the displacement accuracy requirements of lead wire forming processing, and thus ensure the stability of overall processing quality.

[0046] Furthermore, this embodiment also provides a lead forming method for a PFC inductor, which is based on the lead forming apparatus for PFC inductor processing described above, and includes the following steps: 101. Place the semi-finished inductor 200 at the wire drawing station 101; 102. The cable clamp 12 is closed by the cable pull cylinder 13 to clamp the shorter first pin 201 of the semi-finished inductor 200. 103. Drive the wire pulling slide block 11 to move away from the wire pulling station 101 by the wire pulling drive module 14, and stretch the first pin 201 to the same length as the second pin 202. 104. The first twisting assembly 21 applies a twist around the axis of the first pin 201 and the second pin 202 of the semi-finished inductor 200 after the wire is drawn. 105. The first pin 201 and the second pin 202 of the semi-finished inductor 200 are bent downward from an inclined state relative to the semi-finished inductor 200 to a vertical state by means of the second twisting assembly 22.

[0047] In this embodiment, step 101 specifically includes: 1011. Place the semi-finished inductor 200 to be processed into the positioning groove 321 on the positioning seat 32 of the inductor positioning conveying mechanism 30 at the loading station 104, and use the positioning component 33 to position the semi-finished inductor 200. 1012. The first pin 201 of the semi-finished inductor 200 is lifted by the top wire assembly 37, and the first pin 201 is lifted to the height that engages with the wire clamp 12 of the wire pulling mechanism 10. 1013. The rotating assembly 36 drives the rotating seat 361 to rotate, which in turn drives the positioning seat 32 to rotate, causing the semi-finished inductor 200 to rotate, thereby rotating the first pin 201 to an angle that engages with the wire clamp 12 of the wire pulling mechanism 10. 1014. Drive the sliding frame 31 to the wire drawing station 101 via the inductor conveying module 34 to convey the semi-finished inductor 200 to the wire drawing station 101.

[0048] In this embodiment, step 102 specifically includes: 1021. The wire pulling drive module 14 drives the wire pulling slide seat 11 to move toward the wire pulling station 101, and makes the first pin 201 of the semi-finished inductor 200 delivered to the wire pulling station 101 located in the clamping end of the wire pulling clamp 12. 1022. The cable clamp 12 is closed by the cable cylinder 13 to clamp the first pin 201; In this embodiment, step 103 specifically includes: 1031. The wire pulling drive module 14 drives the wire pulling slide seat 11 to move away from the wire pulling station 101, thereby causing the wire pulling clamp 12 to move away from the wire pulling station 101, thereby stretching the first pin 201 to the same length as the second pin 202. 1032. After the first pin 201 is stretched, the wire pulling cylinder 13 drives the wire pulling clamp 12 to open and release the first pin 201. At this time, the semi-finished inductor 200 with the first pin 201 stretched is transported back to the loading station 104 through the inductor conveying module 34. In this embodiment, step 104 specifically includes: 1041. The first transfer robot 42 of the transfer mechanism 40 transfers the semi-finished inductor 200 with the first pin 201 stretched to the first twisted wire carrier 210 on the first twisted wire carrier 210 on the first twisted wire carrier 102 at the loading station 104, and clamps and fixes it by the clamping component 219. 1042. The first twisting bearing seat 210 is driven to rotate by the first twisting rotary motor 218, which in turn drives the semi-finished inductor 200 to rotate, so that the first pin 201 and the second pin 202 of the semi-finished inductor 200 are adjusted to a suitable posture before twisting, so that the two first twisting jaws 213 can accurately and smoothly clamp the first pin 201 and the second pin 202. 1043. The first twisted wire sliding seat 212 is driven by the first twisted wire sliding cylinder 214 to move towards the first twisted wire bearing seat 210, so that the first pin 201 and the second pin 202 are respectively located in the clamping ends of the two first twisted wire clamping claws 213. Then, the two first twisted wire clamping claws 213 are driven by the two first clamping claw cylinders 215 to close, so that the two first twisted wire clamping claws 213 clamp the first pin 201 and the second pin 202. 1044. The first twisting rotary cylinder 216 drives the two first twisting jaws 213 to rotate, thereby applying a twist about their own axis to the first pin 201 and the second pin 202. In this embodiment, step 105 specifically includes: 1051. The semi-finished inductor 200 on the first twisted wire carrier 210 is transferred to the second twisted wire carrier 222 on the second twisted wire station 103 by the second transfer robot 43 of the transfer mechanism 40. 1052. The two second twisted wire sliding seats 223 are driven by the second twisted wire sliding cylinder 225 to move toward the direction of the second twisted wire bearing seat 222, so that the first pin 201 and the second pin 202 are respectively located in the clamping end of the two second twisted wire clamping jaws 224. Then, the two second twisted wire clamping jaws 224 are driven by the two second clamping jaw cylinders 226 to close, so that the two second twisted wire clamping jaws 224 clamp the first pin 201 and the second pin 202. 1053. The second twisting rotary cylinder 227 drives the two second twisting jaws 224 to rotate, so that the first pin 201 and the second pin 202 are bent downward from the inclined state relative to the semi-finished inductor 200 to the vertical state, thus completing the twisting forming of the semi-finished inductor 200.

[0049] In addition, the lead forming method for a PFC inductor provided in this embodiment also includes step 106, transferring the semi-finished inductor 200 on the second twisted wire carrier 222 to the unloading station 105 by the third transfer robot 44 of the transfer mechanism 40, and using the unloading mechanism 50 to transport and unload the semi-finished inductor 200.

[0050] The above is only used to illustrate the technical solution of the present invention and is not intended to limit it. Any other modifications or equivalent substitutions made by those skilled in the art to the technical solution of the present invention, as long as they do not depart from the spirit and scope of the technical solution of the present invention, should be covered within the scope of the claims of the present invention.

Claims

1. A lead forming apparatus for PFC inductor processing, characterized in that, It includes a body (100) and a wire pulling mechanism (10) and a wire twisting mechanism (20) provided on the body (100), wherein the body (100) is provided with a wire pulling station (101); The wire pulling mechanism (10) is located at the wire pulling station (101) and includes a wire pulling slide seat (11) slidably mounted on the machine body (100), a wire pulling clamp (12) mounted on the wire pulling slide seat (11), a wire pulling cylinder (13) for driving the wire pulling clamp (12) to open and close, and a wire pulling drive module (14) for driving the wire pulling slide seat (11) to move toward or away from the wire pulling station (101). The wire pulling cylinder (13) drives the wire pulling clamp (12) to close to clamp the first pin (201) of the semi-finished inductor (200), and the wire pulling drive module (14) drives the wire pulling slide seat (11) to move away from the wire pulling station (101) to stretch the first pin (201) to the same length as the second pin (202). The twisting mechanism (20) includes a first twisting assembly (21) and a second twisting assembly (22). The first twisting assembly (21) is used to apply a twist around the axis of the first pin (201) and the second pin (202) of the semi-finished inductor (200). The second twisting assembly (22) is used to bend the first pin (201) and the second pin (202) of the semi-finished inductor (200) from an inclined state relative to the semi-finished inductor (200) downward to a vertical state.

2. The lead forming apparatus for PFC inductor processing according to claim 1, characterized in that, The first twisted wire assembly (21) includes a first twisted wire support (210) for carrying a semi-finished inductor (200), two first twisted wire fixing seats (211) symmetrically arranged on both sides of the first twisted wire support (210), a first twisted wire sliding seat (212) slidably arranged on the first twisted wire fixing seat (211), a first twisted wire clamp (213) arranged on the first twisted wire sliding seat (212), a first twisted wire sliding cylinder (214) for driving the first twisted wire sliding seat (212) to move towards or away from the first twisted wire support (210), a first clamp cylinder (215) for driving the first twisted wire clamp (213) to open and close, and a first twisted wire rotating cylinder (216) for driving the first twisted wire clamp (213) to rotate. The first twisted wire support (210) is provided with a first support groove (2101) for carrying the semi-finished inductor (200).

3. The lead forming device for PFC inductor processing according to claim 2, characterized in that, The first twisted wire assembly (21) further includes a first twisted wire fixing frame (217), a first twisted wire rotary motor (218) disposed on the first twisted wire fixing frame (217), and a clamping component (219) disposed on the first twisted wire support (210). The first twisted wire support (210) is rotatably disposed on the first twisted wire fixing frame (217). The first twisted wire rotary motor (218) is used to drive the first twisted wire support (210) to rotate, so that the first twisted wire gripper (213) can smoothly clamp the first pin (201) and the second pin (202) of the semi-finished inductor (200). The clamping component (219) is used to clamp the semi-finished inductor (200) against the first support groove (2101).

4. The lead forming apparatus for PFC inductor processing according to claim 3, characterized in that, The second twisted wire assembly (22) includes a second twisted wire fixing frame (221), a second twisted wire support seat (222) fixedly mounted on the second twisted wire fixing frame (221), two symmetrically arranged second twisted wire sliding seats (223) that can slide towards or away from the second twisted wire support seat (222), a second twisted wire gripper (224) mounted on the second twisted wire sliding seat (223), a second twisted wire sliding cylinder (225) for driving the second twisted wire sliding seat (223) to move towards or away from the second twisted wire support seat (222), and a second gripper cylinder (226) for driving the second twisted wire gripper (224) to open and close. The second twisted wire bearing seat (222) is provided with a second bearing groove (2221) for bearing the semi-finished inductor (200), and the second twisted wire rotating cylinder (227) is fixedly mounted on the second twisted wire sliding seat (223). A mounting plate (228) is fixedly mounted on the output end of the second twisted wire rotating cylinder (227). The second gripper cylinder (226) is fixedly mounted on the mounting plate (228), and the output ends of the second gripper cylinder (226) and the second twisted wire rotating cylinder (227) are offset.

5. The lead forming apparatus for PFC inductor processing according to claim 1, characterized in that, It also includes an inductor positioning and conveying mechanism (30). The machine body (100) is provided with a loading station (104). The inductor positioning and conveying mechanism (30) includes a sliding frame (31) slidably disposed between the loading station (104) and the wire pulling station (101), a positioning seat (32) disposed on the sliding frame (31), a positioning component (33) disposed on the positioning seat (32), and an inductor conveying module (34) for driving the sliding frame (31) to move back and forth between the loading station (104) and the wire pulling station (101). The positioning seat (32) is provided with a positioning groove (321) for positioning the semi-finished inductor (200). One side of the positioning groove (321) is open. The positioning component (33) is located on one side of the opening of the positioning groove (321) and is used to press the semi-finished inductor (200) against the positioning groove (321).

6. The lead forming apparatus for PFC inductor processing according to claim 5, characterized in that, The inductive positioning and conveying mechanism (30) further includes a rotating seat (35), a rotating component (36), and a top wire component (37). The rotating seat (35) is rotatably connected to the sliding frame (31). The positioning seat (32) is fixedly mounted on the rotating seat (35). The rotating component (36) is mounted on the sliding frame (31) to drive the rotating seat (35) to rotate relative to the sliding frame (31). The top wire component (37) is mounted on the rotating seat (35) to lift the first pin (201) to a height that cooperates with the wire pulling mechanism (10).

7. The lead forming apparatus for PFC inductor processing according to claim 6, characterized in that, The rotating assembly (36) includes a rotating seat (361) fixedly mounted on the sliding frame (31) and an inductive positioning rotary motor (362). The rotating seat (35) is fixedly mounted on the rotating seat (361), and the output shaft of the inductive positioning rotary motor (362) is fixedly connected to the rotating seat (361) to drive the rotating seat (361) to rotate relative to the sliding frame (31).

8. The lead forming apparatus for PFC inductor processing according to claim 7, characterized in that, The top wire assembly (37) includes a top wire block (371) slidably disposed on a positioning seat (32) and a top wire cylinder (372) for driving the top wire block (371) to move toward or away from the positioning groove (321). The top wire block (371) is inclined relative to the positioning seat (32), and the inclination angle of the top wire block (371) is consistent with the initial inclination angle of the first pin (201). A guide surface is provided on the side of the top wire block (371) facing the positioning groove (321). The guide surface is used to contact and lift the first pin (201) when the top wire block (371) moves toward the positioning groove (321).

9. The lead forming apparatus for PFC inductor processing according to claim 5, characterized in that, It also includes a transfer mechanism (40) and a feeding mechanism (50). The twisting mechanism (20) is located on one side of the inductor positioning and conveying mechanism (30), and the feeding mechanism (50) is located on the side of the twisting mechanism (20) away from the inductor positioning and conveying mechanism (30). The transfer mechanism (40) spans the inductor positioning and conveying mechanism (30), the twisting mechanism (20) and the feeding mechanism (50), and is used to transfer the semi-finished inductor (200) after stretching on the inductor positioning and conveying mechanism (30) to the twisting mechanism (20), and to convey the twisted semi-finished inductor (200) to the feeding mechanism (50) for feeding.

10. A method for forming the leads of a PFC inductor, based on the lead forming apparatus for PFC inductor processing as described in any one of claims 1-9, characterized in that, Includes the following steps: Place the semi-finished inductor (200) at the wire drawing station (101); The cable clamp (12) is closed by the cable cylinder (13) to clamp the shorter first pin (201) of the semi-finished inductor (200); The wire pulling drive module (14) drives the wire pulling slide (11) to move away from the wire pulling station (101) and stretch the first pin (201) to the same length as the second pin (202); The first twisting assembly (21) applies a twist around the axis of the first pin (201) and the second pin (202) of the semi-finished inductor (200) after the wire is drawn. The first pin (201) and the second pin (202) of the semi-finished inductor (200) are bent downward from an inclined state relative to the semi-finished inductor (200) to a vertical state by the second twisting assembly (22).

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