A high-speed rotating winding mechanism with automatic variable pitch and a winding method

Abstract

The application relates to the technical field of wire harness processing equipment, and discloses an automatic variable-distance high-speed rotary winding mechanism and a winding method, which comprise coaxially arranged rotary modules and variable-distance modules; the rotary modules drive the whole winding mounting base to rotate; a variable-distance shaft of the variable-distance modules is coaxially arranged in the winding mounting base and can rotate relatively; a variable-distance cam groove plate is fixed to the front end of the variable-distance shaft, and a cam groove conforming to an Archimedes spiral equation is arranged on the end face of the variable-distance cam groove plate; a plurality of winding support units are radially slidably arranged at the front end of the winding mounting base and are driven by being embedded into the cam groove through the variable-distance cam. The linear variable-distance characteristic of the Archimedes spiral is utilized to accurately control the winding support diameter through the rotation angle, the winding precision is high, and the coil consistency is good; the winding plate can be radially contracted to realize non-pulling demolding, and the product yield is significantly improved; the whole machine structure is compact, the motion coordination is strong, the whole process can be automatically operated, and the high-speed winding processing of wire harnesses with different specifications is adapted.

Description

Technical Field

[0001] This invention relates to the field of wire harness processing equipment technology, specifically to an automatic variable-pitch high-speed rotary winding mechanism and winding method. Background Technology

[0002] In the field of wire harness processing equipment technology, automatic variable pitch high-speed rotary winding is a core process in wire harness production in industries such as electronics, electrical engineering, and new energy. The automatic variable pitch high-speed rotary winding mechanism can match processes such as fixed-length cutting and coil bundling to complete the wire harness winding and unwinding processing. It can replace traditional manual winding and semi-automatic winding equipment, improve production efficiency, reduce labor costs, and is widely used in the winding and forming processing of various incoming wire harnesses.

[0003] Currently available rotary winding mechanisms suffer from several structural and operational defects: First, the pitch-changing mechanism is a simple, manually adjustable structure that cannot be matched with the production processes of automated equipment; second, the winding support plate is a fixed structure, preventing the wire bundle from shrinking after winding, which easily pulls the wire and wears the insulation layer during demolding; third, some winding support plates on the market can automatically change pitch, but the pitch-changing drive control is inaccurate, and the pitch change size is irregular, resulting in large errors in the winding thread length, making automatic correction of the thread length impossible, and manual adjustment difficult. These structural design defects in existing mechanisms are the main reasons restricting winding accuracy, product yield, and production cycle time. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic variable-pitch high-speed rotary winding mechanism and winding method, which solves the problems in the prior art.

[0005] The present invention adopts the following technical solution: An automatic variable-pitch high-speed rotary winding mechanism includes a rotary module and a variable-pitch module arranged coaxially. The rotating module includes a winding mounting base rotatable about its own axis and a rotation drive assembly for driving the winding mounting base to rotate. The variable pitch module includes a variable pitch shaft, a variable pitch drive assembly, a variable pitch cam groove plate, and at least two sets of winding support units. The variable pitch shaft is coaxially inserted inside the winding mounting base, and the variable pitch shaft and the winding mounting base are rotatable relative to each other. The variable pitch drive assembly is driven by the variable pitch shaft and is used to drive the variable pitch shaft to rotate around its own axis. The variable pitch cam groove plate is fixedly installed at the front end of the variable pitch shaft, and the end face of the variable pitch cam groove plate facing the winding support unit has at least two cam grooves, the trajectory of which conforms to the Archimedean spiral equation. Each winding support unit includes a guide rail mounting block, a winding plate, and a variable pitch cam; the guide rail mounting block is slidably mounted on the front end face of the winding mounting base along the radial direction of the winding mounting base, the winding plate is fixed to the outer end of the guide rail mounting block, and the variable pitch cam is fixed to the inner end of the guide rail mounting block, and the variable pitch cam is correspondingly embedded in the cam groove. When the variable pitch shaft rotates relative to the winding mounting base, the sidewall of the cam groove pushes the variable pitch cam to move radially, thereby causing the guide rail mounting block and the winding plate to slide radially synchronously, so as to adjust the winding support diameter formed by all the winding plates.

[0006] Preferably, a wire end clamping assembly is provided at the front center of the winding mounting base. The wire end clamping assembly includes a clamp and a clamping drive for driving the clamp (opening and closing clamp).

[0007] Preferably, the gripper drive is a first-end gripper cylinder; the rotating module further includes a slip ring, which is coaxially sleeved on the outer periphery of the winding mounting base, and the rotating side of the slip ring is connected to the air passage of the first-end gripper cylinder for supplying compressed gas to the first-end gripper cylinder in the rotating state.

[0008] Preferably, the rotary drive assembly includes a rotary motor and a rotary transmission mechanism, wherein the rotary motor is connected to the winding mounting base via the rotary transmission mechanism.

[0009] Preferably, the variable pitch drive component is a variable pitch motor, the variable pitch motor is a servo motor, the servo motor is electrically connected to a control system, and the control system has a built-in line length-rotation angle conversion module, which is used to calculate the target rotation angle of the variable pitch shaft according to the set wire harness length, so as to control the winding support diameter to match the number of winding turns.

[0010] Preferably, the number of the winding support units is 3-6 sets, and all the winding support units are evenly arranged in a ring around the axis of the winding mounting base.

[0011] Preferably, an auxiliary support assembly is provided on the side of the variable pitch cam groove plate facing away from the winding support unit. The auxiliary support assembly includes a mounting plate fixed to the winding mounting base. A plurality of universal balls are arranged on the mounting plate, and the spherical surface of the universal balls abuts against the end face of the variable pitch cam groove plate.

[0012] Preferably, the mounting plate is coaxially rotated with the pitch shaft via a rotating shaft.

[0013] Preferably, an automatic variable-pitch high-speed winding method includes the following steps: S1 Wire End Fixing: Fix the beginning of the wire harness to the front end of the winding mounting base; S2 Support Diameter Variable Pitch: The variable pitch drive assembly drives the variable pitch shaft (304) to rotate in the positive direction relative to the winding mounting seat. The variable pitch cam groove plate (302) rotates synchronously with the variable pitch shaft (304). The cam groove pushes the variable pitch cam (306) to move outward radially, causing each winding plate (301) to move outward synchronously to the preset winding support diameter. S3 Rotary winding: The rotary drive assembly drives the winding mounting base to drive all the winding support units to rotate synchronously a preset number of turns, winding the wire harness around the outer periphery of each winding plate (301) to form a wire harness coil; S4 Diameter Reduction Demolding: The variable pitch drive assembly drives the variable pitch shaft (304) to rotate in the opposite direction relative to the winding mounting base, causing each winding plate (301) to shrink inward synchronously, so that the inner ring of the wire harness coil is separated from the outer wall of the winding plate (301). S5 Material Reset: After removing the wire harness coil, the winding mounting base rotates back to the initial angle to complete the reset.

[0014] The beneficial effects of this invention are as follows: Using an Archimedean spiral trajectory cam groove as the variable pitch transmission structure, its extreme diameter and rotation angle have a strictly linear relationship. For every unit angle rotation of the variable pitch motor, the radial displacement of the winding plate remains constant, and the variable pitch law can be quantified. Combined with servo drive and a wire length-rotation angle conversion algorithm, the winding diameter and number of turns can be automatically calculated and controlled according to the set wire harness length, eliminating manual adjustment errors. The coil size tolerance control accuracy is improved by an order of magnitude, resulting in excellent consistency in mass production and adaptability to high-precision wire harness assembly requirements.

[0015] The winding board adopts a radially expandable structure. After the wire harness is wound, the winding board first shrinks inward to form a demolding gap before taking out the material. There is no rigid friction or pulling between the coil and the support structure, which solves the problems of wire harness deformation and insulation layer scratches caused by traditional fixed support demolding. This improves product yield and reduces production losses.

[0016] The rotary module and the pitch-changing module adopt a coaxial integrated design, which is compact in structure and has a short transmission chain. The pitch-changing action and the rotation action are precisely linked through the control system: the rotation winding is started after the pitch is in place. During the winding process, the pitch-changing shaft and the winding mounting base rotate synchronously, and the winding diameter remains constant, ensuring uniform wire tension and neat wire arrangement. This avoids the loosening and wire breakage problems caused by asynchronous movement of traditional mechanisms, and improves the stability of winding quality.

[0017] The machine achieves fully automated operation of the entire process, including wire end clamping, precise pitch adjustment, rotary winding, shrinkage demolding, and mechanism reset, without manual intervention. The winding cycle time for a single wire harness is shorter than that of semi-automatic equipment, allowing direct integration with high-speed wire harness processing production lines while reducing labor costs. Furthermore, parameters such as the number of coils and coil diameter can be flexibly adjusted via the program to adapt to the winding requirements of incoming wire harnesses with different lengths and diameters. The core modular design facilitates installation, maintenance, and upkeep; changing processing specifications requires only program parameter adjustments without replacing the mechanical structure, resulting in low equipment debugging costs. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the rotating module structure of the present invention; Figure 3 This is a schematic diagram of the front-end structure of the variable pitch module of the present invention; Figure 4 This is a schematic diagram of the auxiliary support component structure of the variable pitch module of the present invention; Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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 are within the scope of protection of the present invention.

[0020] Embodiments of the present invention: like Figures 1-4 As shown, the present invention provides an automatic variable pitch high-speed rotary winding mechanism, which is divided into two main parts: variable pitch module I and rotary module II. The two are coaxially integrated and arranged, with a compact structure and high transmission efficiency.

[0021] The rotating module II mainly includes a winding mounting base (not separately labeled in the figure, which is the main base of the rotating part), a rotating transmission mechanism 201, a rotating motor 202, and a slip ring 203. The rotating motor 202 is fixedly mounted on the equipment frame and drives the winding mounting base to rotate at high speed around its own axis through the rotating transmission mechanism 201 (which can be in the form of synchronous belt drive, gear drive, etc.). The slip ring 203 is coaxially sleeved on the outer circumference of the winding mounting base. Its fixed side is connected to an external air source / power source, and its rotating side rotates synchronously with the winding mounting base, used to transmit power and signals to the front-end pneumatic and electrical components in the rotating state.

[0022] The variable pitch module I mainly includes a variable pitch shaft 304, a variable pitch motor 305, a variable pitch cam slot plate 302, and four sets of winding support units. The four sets of winding support units are evenly distributed in a 90° ring around the axis.

[0023] The variable pitch shaft 304 is coaxially mounted in the center hole of the winding mounting base, and the two are rotatably engaged by bearings, allowing them to rotate independently relative to each other. The variable pitch motor 305 is a high-precision servo motor, mounted at the rear of the equipment, and its output shaft is connected to the rear end of the variable pitch shaft 304 for driving the variable pitch shaft 304 to rotate around its own axis.

[0024] The variable-pitch cam slot plate 302 is a circular disc structure, centrally fixedly mounted at the front end of the variable-pitch shaft 304, and rotates synchronously with the variable-pitch shaft 304. The front end face of the variable-pitch cam slot plate 302 has four cam slots, and the trajectory of each cam slot conforms to the Archimedean spiral equation, whose polar coordinate equation is: r = a + bθ, where r is the polar radius, θ is the polar angle, a is the initial polar radius, and b is the helix coefficient.

[0025] The characteristic of this equation is that the change in the extreme diameter is strictly proportional to the change in the rotation angle. That is, for every unit angle that the cam slot plate rotates, the radial displacement of the variable pitch cam 306 is constant, thereby achieving linear and precisely calculable variable pitch control.

[0026] Each winding support unit consists of a guide rail mounting block 303, a winding plate 301, and a variable pitch cam 306. A radially extending linear guide rail is fixed to the front end face of the winding mounting base. The guide rail mounting block 303 is slidably mounted on the linear guide rail and can only move radially back and forth. The winding plate 301 is an arc-shaped plate structure, fixedly mounted on the outer end of the guide rail mounting block 303. The outer arc surfaces of the four winding plates 301 together form the outer circumferential surface of the winding support. The variable pitch cam 306 is fixedly mounted on the inner end of the guide rail mounting block 303 and correspondingly embedded in the cam groove of the variable pitch cam groove plate 302, rolling in cooperation with the side wall of the cam groove.

[0027] When the variable pitch motor 305 drives the variable pitch shaft 304 to rotate relative to the winding mounting base, the variable pitch cam groove plate 302 rotates synchronously. The side wall of the cam groove pushes the variable pitch cam 306 to move radially, which in turn drives the winding plate 301 to extend or retract radially synchronously through the guide rail mounting block 303, thereby achieving precise adjustment of the winding support diameter.

[0028] At the front center of the winding mounting base, a wire end clamping assembly is also provided, including a head end clamping cylinder 101 and a clamping jaw 102. The air passage of the head end clamping cylinder 101 is connected to an external air source through a slip ring 203, which can stably drive the clamping jaw 102 to open and close even in high-speed rotation, thereby realizing the clamping and release of the wire harness head end.

[0029] Specifically, to improve the rotational stability of the variable-pitch cam groove plate 302 and reduce end face runout under high-speed rotation, an auxiliary support assembly is provided on the rear side of the variable-pitch cam groove plate 302. This assembly includes a mounting plate 402 and multiple universal balls 401. The mounting plate 402 is coaxially engaged with the variable-pitch shaft 304 via a rotating shaft 403, and the mounting plate 402 is relatively fixed to the winding mounting seat. The multiple universal balls 401 are evenly distributed on the front end face of the mounting plate 402, and the spherical surfaces abut against the rear end face of the variable-pitch cam groove plate 302 to form rolling support, which not only ensures smooth rotation but also counteracts the axial reaction force of the variable-pitch cam, thereby improving the stability of the mechanism during high-speed operation.

[0030] In this embodiment, both the variable pitch motor 305 and the rotary motor 202 are connected to the equipment control system, which has a built-in line length-rotation angle conversion module. After the operator inputs the target wire harness length, the system can automatically calculate the matching number of winding coils and winding diameter, and then calculate the target rotation angle of the variable pitch shaft 304 based on the parameters of the Archimedean spiral, accurately controlling the operation of the variable pitch motor 305 and achieving automatic matching of all parameters.

[0031] As one possible implementation method, the automatic variable-pitch high-speed winding method using the mechanism described in Example 1 has the following specific workflow: Standby state: The winding mounting base is stopped at the set initial angle, each winding plate 301 is in the retracted state, and the grippers 102 are open, waiting for material to arrive.

[0032] Wire end clamping: The preceding robotic arm clamps the cut wire bundle to a fixed length and sends it to the winding station. The first end clamping cylinder 101 is activated, driving the clamping jaw 102 to close and clamp the first end of the wire bundle.

[0033] Pitch variation: The control system sends a forward rotation command to the pitch variation motor 305 according to the preset wire harness parameters; the pitch variation shaft 304 drives the pitch variation cam groove plate 302 to rotate forward by a specified angle, and the cam groove pushes the four pitch variation cams 306 to move outward in the radial direction in sync, driving the winding plate 301 to extend to the target winding diameter position and lock it.

[0034] Rotary winding: After the pitch is adjusted to the desired position, the rotary motor 202 starts and drives the winding mounting base to rotate at high speed through the rotary transmission mechanism 201. At this time, the pitch shaft 304 and the winding mounting base remain relatively stationary, and the winding diameter is constant. The wire harness is evenly wound around the outer circumference of the four winding plates 301. After reaching the preset number of turns, the rotary motor stops, forming a tensioned wire harness coil.

[0035] Shrinkage demolding: The variable pitch motor 305 rotates in the opposite direction at a specified angle, causing the variable pitch cam groove plate 302 to reverse. The winding plate 301 shrinks radially inward. The wire harness coil maintains its shape due to its own elasticity, and a uniform demolding gap is formed between its inner ring and the outer wall of the winding plate 301.

[0036] Material Retrieval and Reset: The end effector reaches in to pick up the wire harness coil and sends it to the next bundling station; then the winding mounting base rotates back to the initial angle, the gripper 102 opens, and the mechanism returns to the standby state, ready for the next cycle of operation.

[0037] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. 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. An automatic variable-pitch high-speed rotary winding mechanism, characterized in that, Including a coaxially arranged rotary module (II) and a variable pitch module (I); The rotating module (II) includes a winding mounting base that can rotate about its own axis and a rotating drive assembly for driving the winding mounting base to rotate. The variable pitch module (I) includes a variable pitch shaft (304), a variable pitch drive assembly, a variable pitch cam groove plate (302), and at least two sets of winding support units. The variable pitch shaft (304) is coaxially inserted inside the winding mounting base, and the variable pitch shaft (304) and the winding mounting base are rotatable relative to each other; the variable pitch drive assembly is connected to the variable pitch shaft (304) for driving the variable pitch shaft (304) to rotate around its own axis; the variable pitch cam groove plate (302) is fixedly installed at the front end of the variable pitch shaft (304), and the end face of the variable pitch cam groove plate (302) facing the winding support unit has at least two cam grooves, the trajectory of which conforms to the Archimedean spiral equation; Each of the winding support units includes a guide rail mounting block (303), a winding plate (301), and a variable pitch cam (306); the guide rail mounting block (303) is slidably mounted on the front end face of the winding mounting base along the radial direction of the winding mounting base, the winding plate (301) is fixed to the outer end of the guide rail mounting block (303), and the variable pitch cam (306) is fixed to the inner end of the guide rail mounting block (303), and the variable pitch cam (306) is correspondingly embedded in the cam groove; When the variable pitch shaft (304) rotates relative to the winding mounting base, the side wall of the cam groove pushes the variable pitch cam (306) to move radially, thereby driving the guide rail mounting block (303) and the winding plate (301) to slide radially synchronously, so as to adjust the winding support diameter formed by all the winding plates (301).

2. The automatic variable-pitch high-speed rotary winding mechanism according to claim 1, characterized in that, A wire end clamping assembly is provided at the front center of the winding mounting base. The wire end clamping assembly includes a clamp (102) and a clamp driving component for driving the clamp (102) to open and close.

3. The automatic variable-pitch high-speed rotary winding mechanism according to claim 2, characterized in that, The gripper drive is a first-end gripper cylinder (101); the rotating module also includes a slip ring (203), which is coaxially sleeved on the outer periphery of the winding mounting base. The rotating side of the slip ring (203) is connected to the air passage of the first-end gripper cylinder (101) and is used to deliver compressed gas to the first-end gripper cylinder (101) in the rotating state.

4. The automatic variable-pitch high-speed rotary winding mechanism according to claim 3, characterized in that, The rotary drive assembly includes a rotary motor (202) and a rotary transmission mechanism (201), wherein the rotary motor (202) is connected to the winding mounting base via the rotary transmission mechanism (201).

5. The automatic variable-pitch high-speed rotary winding mechanism according to claim 1, characterized in that, The variable pitch drive component is a variable pitch motor (305), which is a servo motor. The servo motor is electrically connected to a control system. The control system has a built-in line length-rotation angle conversion module, which is used to calculate the target rotation angle of the variable pitch shaft (304) according to the set wire harness length, so as to control the winding support diameter to match the number of winding turns.

6. The automatic variable-pitch high-speed rotary winding mechanism according to claim 1, characterized in that, The number of winding support units is 3-6 sets, and all winding support units are evenly arranged in a ring around the axis of the winding mounting base.

7. The automatic variable-pitch high-speed rotary winding mechanism according to claim 1, characterized in that, An auxiliary support assembly is provided on one side of the variable pitch cam groove plate (302) facing away from the winding support unit. The auxiliary support assembly includes a mounting plate (402) fixed to the winding mounting base. A plurality of universal balls (401) are arranged on the mounting plate (402), and the spherical surface of the universal balls (401) abuts against the end face of the variable pitch cam groove plate (302).

8. The automatic variable-pitch high-speed rotary winding mechanism according to claim 7, characterized in that, The mounting plate (402) is coaxially rotated with the variable pitch shaft (304) via a rotating shaft (403).

9. An automatic variable-pitch high-speed winding method, employing the automatic variable-pitch high-speed rotary winding mechanism according to any one of claims 1-8, characterized in that, Includes the following steps: S1 Wire End Fixing: Fix the beginning of the wire harness to the front end of the winding mounting base; S2 Support Diameter Variable Pitch: The variable pitch drive assembly drives the variable pitch shaft (304) to rotate in the positive direction relative to the winding mounting seat. The variable pitch cam groove plate (302) rotates synchronously with the variable pitch shaft (304). The cam groove pushes the variable pitch cam (306) to move outward radially, causing each winding plate (301) to move outward synchronously to the preset winding support diameter. S3 Rotary winding: The rotary drive assembly drives the winding mounting base to drive all the winding support units to rotate synchronously a preset number of turns, winding the wire harness around the outer periphery of each winding plate (301) to form a wire harness coil; S4 Diameter Reduction Demolding: The variable pitch drive assembly drives the variable pitch shaft (304) to rotate in the opposite direction relative to the winding mounting base, causing each winding plate (301) to shrink inward synchronously, so that the inner ring of the wire harness coil is separated from the outer wall of the winding plate (301). S5 Material Reset: After removing the wire harness coil, the winding mounting base rotates back to the initial angle to complete the reset.

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