Door type coil automatic forming machine

Abstract

The present application relates to the technical field of forming machine, in particular to a door type coil automatic forming machine, which comprises a cabinet and a mounting plate arranged on the cabinet, and a protective cover composed of a profile and a cabinet door is arranged outside the cabinet; a straightening mechanism, a paint removal mechanism, a soldering mechanism and a forming mechanism are sequentially arranged on the mounting plate along the conveying direction of the copper wire; the straightening mechanism comprises two groups of straightening units arranged at an angle of 90 degrees and used for horizontal and vertical straightening respectively; the straightening mechanism utilizes two groups of straightening units arranged at an angle of 90 degrees, which can effectively eliminate the copper wire curling stress and provide a straight wire base for subsequent processing; the paint removal mechanism applies a stable pressing force to the copper wire through the close cooperation of the pressing block in the lifting and pressing dust removal linkage assembly and the bearing plate guide groove, and cooperates with the scrap suction elbow which moves synchronously to the nearby polishing position, which can significantly avoid the problem of uneven paint removal length caused by copper wire bouncing during polishing.

Description

Technical Field

[0001] This invention relates to the field of molding machine technology, specifically to an automatic forming machine for gate-shaped coils. Background Technology

[0002] Portal coils are core components in electrical devices such as electronic transformers, inductors, and relays. Their processing quality directly determines the electrical performance and service life of the devices. In the production process, they usually require multiple steps, including copper wire unwinding and straightening, surface insulation varnish removal, end tinning, and fixed-length bending and cutting. With the improvement of automated manufacturing, integrating the above-mentioned scattered processes into one unit to achieve efficient and continuous processing of copper wire from feeding to finished product forming has become an important development direction for portal coil forming equipment in the industry.

[0003] However, existing automatic forming equipment for gate-type coils still has significant shortcomings at certain workstations. On the one hand, there is a lack of effective wire locking and dust collection structures during the paint stripping process. During the polishing process, the copper wire is prone to bouncing, resulting in uneven paint stripping lengths, and the spilled paint debris pollutes the processing environment. On the other hand, the wire lacks pre-clamping at the moment of cutting by the push knife, which easily causes slippage and results in large cutting dimension errors. After forming and bending, the finished coil often gets stuck between the cutter or mandrel. There is a lack of a demolding structure that can automatically retract so that the product can fall off by gravity. The overall forming efficiency and processing yield still need to be improved.

[0004] Therefore, in view of the above situation, there is an urgent need to develop an automatic forming machine for gate-shaped coils to overcome the shortcomings in current practical applications and meet current needs. Summary of the Invention

[0005] The purpose of this invention is to provide an automatic forming machine for gate-shaped coils to solve the problems of lack of effective clamping and dust removal during paint stripping, easy slippage of copper wires during cutting leading to dimensional deviations, and finished products stuck at the processing position after forming, making them difficult to demold and fall off.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an automatic forming machine for door-shaped coils, comprising: a cabinet and a mounting plate disposed on the cabinet, wherein the cabinet is provided with a protective cover consisting of profiles and cabinet doors.

[0007] A straightening mechanism, a paint stripping mechanism, a soldering mechanism, and a forming mechanism are sequentially arranged on the mounting plate along the copper wire conveying direction.

[0008] The straightening mechanism includes two sets of straightening units arranged at a 90° angle and used for horizontal and vertical straightening respectively;

[0009] The paint stripping mechanism includes a polishing motor and a polishing head located at the output end of the polishing motor. The polishing head is located directly above the copper wire. The paint stripping mechanism is also equipped with a linear module for driving the polishing head to perform horizontal reciprocating motion and vertical lifting motion, as well as a lifting and pressing dust removal linkage component for pressing down and locking the copper wire during polishing.

[0010] The forming mechanism includes a vertical plate, multiple sets of pusher assemblies arranged around the copper wire processing position, a moving feed assembly for pulling the copper wire to move along the conveying direction, and a mandrel ejection assembly; the mandrel ejection assembly is configured to extend to the processing position to provide positioning support when the copper wire is bent and formed, and to retract backward to drop the formed coil after forming is completed.

[0011] Preferably, each straightening unit of the straightening mechanism includes a cage, multiple adjusting sliders slidably disposed within the cage, straightening wheels rotatably disposed on the adjusting sliders, and a screw adjusting assembly passing through the cage and connected to the adjusting sliders. The outer end of the screw adjusting assembly is provided with a handwheel for adjusting the spacing between the straightening wheels, and the multiple straightening wheels of the same straightening unit are staggered along the direction of the copper wire.

[0012] Preferably, the paint stripping mechanism includes a paint stripping station mounting frame, and the linear module includes a horizontal linear module mounted on the paint stripping station mounting frame and a vertical adjustment module mounted on the output end of the horizontal linear module.

[0013] The horizontal linear module includes a first slider rail module, a first mounting plate slidably disposed on the first slider rail module, and a first driving component for driving the first mounting plate to slide horizontally.

[0014] The vertical adjustment module includes a second slider rail module mounted on a first mounting plate, a motor plate slidably mounted on the second slider rail module, and a vertical drive assembly for driving the motor plate to move up and down along the second slider rail module. The motor is horizontally inserted and fixed on the motor plate.

[0015] Preferably, a support plate is fixed on the paint stripping station mounting frame;

[0016] The lifting, pressing, and dust removal linkage assembly includes a third slider rail module fixed on the bearing plate, a lifting plate slidably mounted on the third slider rail module, and a vertical drive component fixed on the paint stripping station mounting frame for driving the lifting plate to rise and fall.

[0017] The lifting plate is horizontally spaced with an upper slide and a lower slide. The upper slide has a sliding and lockable pressing slider, which has a pressure block extending towards the copper wire and used to press down and fix the copper wire. The lower slide has a sliding and lockable chip suction slider, which is connected to a chip suction bend. When the vertical drive unit drives the lifting plate to descend, the pressure block presses down on the copper wire and the chip suction bend moves synchronously to the vicinity of the grinding position. The bearing plate has a guide groove for the copper wire to pass through and to cooperate with the upper pressure block to ensure that the force is applied during grinding.

[0018] Preferably, the soldering mechanism includes an adjustable mounting bracket fixed to the mounting plate and a semi-sealed chamber disposed on the adjustable mounting bracket; the semi-sealed chamber has openings on both sides for copper wires to pass through and exit, and a fume vent at the top; a flux box and a solder pot are arranged sequentially inside the semi-sealed chamber along the direction of copper wire travel.

[0019] Preferably, the multiple pusher assemblies include a first pusher assembly, a second pusher assembly, a third pusher assembly, and a fourth pusher assembly;

[0020] The first pusher assembly includes a first mounting bracket on a vertical plate, a first cylinder on the first mounting bracket, a first pusher slider rail module on the vertical plate, a first pusher seat slidably mounted on the first pusher slider rail module, and a first pusher on the first pusher seat. The first pusher seat is driven and connected to the first cylinder.

[0021] The second pusher assembly includes a lifting member on the upright plate, a second cylinder on the lifting member, a second pusher slider rail module on the lifting member, a second pusher seat slidably disposed on the second pusher slider rail module, and a second pusher on the second pusher seat. The second pusher seat is driven and connected to the second cylinder, and the second pusher assembly is disposed opposite to the first pusher assembly.

[0022] The third pusher assembly includes a third mounting plate on the upright plate, a third pusher slider rail module on the third mounting plate, a third pusher seat on the third pusher slider rail module, a third pusher on the third pusher seat, and a third cylinder on the third mounting plate. The third pusher seat is driven and connected to the third cylinder.

[0023] The fourth pusher assembly includes a fourth mounting plate on the vertical plate, a fourth pusher slider rail module on the fourth mounting plate, a fourth pusher seat on the fourth pusher slider rail module, a fourth pusher on the fourth pusher seat, and a fourth cylinder on the fourth mounting plate. The fourth pusher seat is driven and connected to the fourth cylinder. The third pusher assembly and the fourth pusher assembly are located on the left and right sides of the machining position, respectively, and are inclined towards the middle machining position.

[0024] Preferably, an auxiliary plate is provided on the upright plate at the copper wire processing position. The auxiliary plate includes a first support plate and a second support plate respectively provided on the wire entry side and the wire exit side of the processing position. The first support plate has a guide hole for the copper wire to pass through, and the second support plate has a support groove for supporting the end of the copper wire.

[0025] The forming mechanism also includes a pressing component, which is mounted on the upright plate and located at the starting end of the copper wire entering the processing position. It includes a vertically mounted pressing cylinder and a pressing head located at the output end of the pressing cylinder. The upright plate is provided with a bearing position that cooperates with the pressing head. When the pressing head cuts the copper wire with the push knife, it presses down to fix the copper wire and prevents the copper wire from slipping at the moment of cutting.

[0026] Preferably, the mandrel unloading assembly includes a mandrel mounting bracket located on the back of the upright plate and facing the processing position, a drive cylinder horizontally mounted on the mandrel mounting bracket, and a mandrel connected to the output end of the drive cylinder; the upright plate has a clearance hole for the mandrel to pass through; when bending and forming, the drive cylinder drives the mandrel to pass through the clearance hole and extend into the processing position to provide internal support and positioning; after forming is completed, the mandrel is pulled back so that the coil product can fall off by gravity.

[0027] Preferably, the moving feeding assembly includes a second mounting bracket on the back of the upright plate, a screw drive mechanism and a moving slider rail module mounted on the second mounting bracket, and a moving plate connected to and driven by the screw drive mechanism and the moving slider rail module to slide back and forth; the upright plate has an elongated clearance hole for the moving plate to pass through; the end of the moving plate is provided with a gripper cylinder, and the output end of the gripper cylinder is provided with a gripper for gripping copper wire and pulling the copper wire into the forming mechanism under the drive of the moving plate.

[0028] Compared with the prior art, the present invention provides an automatic forming machine for portal coils, which has the following beneficial effects:

[0029] The straightening mechanism utilizes two sets of straightening units arranged at a 90-degree angle to effectively eliminate copper wire curling stress, providing a straight wire foundation for subsequent processing. The paint stripping mechanism applies stable pressure to the copper wire through the tight cooperation between the pressure block and the guide groove of the bearing plate in the lifting, pressing, and dust removal linkage assembly. Combined with the synchronously moving dust-collecting bend near the polishing position, this significantly avoids uneven paint stripping length caused by copper wire bouncing during polishing and achieves immediate collection of paint debris, optimizing the working environment. The soldering mechanism uses a semi-sealed chamber to house the flux box and solder pot, and... The exhaust vent is connected to an external exhaust pipe, effectively preventing the diffusion of harmful gases into the workspace. The pre-set pressing component in the forming mechanism pre-presses the copper wire before the pusher cuts, completely eliminating the risk of wire slippage at the moment of cutting and ensuring the accuracy of processing dimensions. The mandrel ejection component acts as an internal support during forming and quickly retracts after completing all bending and leveling actions, allowing the formed coil to fall smoothly under its own weight without the need for an additional ejection mechanism. This fundamentally solves the industry pain point of finished products getting stuck in the processing position and difficult to demold, greatly improving the overall production efficiency and product yield of the machine. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments 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:

[0031] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0032] Figure 2 This is a front view of the entire invention;

[0033] Figure 3 This is one of the schematic diagrams of the molding mechanism structure of the present invention;

[0034] Figure 4 This is the second schematic diagram of the molding mechanism structure of the present invention;

[0035] Figure 5 This is the third schematic diagram of the molding mechanism structure of the present invention;

[0036] Figure 6 This is a front view of the molding mechanism of the present invention;

[0037] Figure 7 This is a rear view of the molding mechanism of the present invention;

[0038] Figure 8 This is a schematic diagram of the straightening mechanism of the present invention;

[0039] Figure 9This is a schematic diagram of the soldering mechanism of the present invention;

[0040] Figure 10 This is one of the schematic diagrams of the paint stripping mechanism of the present invention;

[0041] Figure 11 This is the second schematic diagram of the paint stripping mechanism of the present invention;

[0042] Figure 12 This is the third schematic diagram of the paint stripping mechanism of the present invention;

[0043] Figure 13 This is the fourth schematic diagram of the paint stripping mechanism of the present invention;

[0044] Figure 14 This is a schematic diagram of the structure of the first driving component of the present invention;

[0045] Figure 15 This is a schematic diagram of the vertical adjustment module structure of the present invention;

[0046] Figure 16 This is a schematic diagram of the lifting, pressing, and dust removal linkage component of the present invention.

[0047] In the diagram: 100, cabinet; 110, mounting platform; 120, protective cover; 200, straightening mechanism; 210, retainer; 220, adjusting slider; 221, straightening wheel; 230, screw adjustment assembly; 231, handwheel; 300, paint stripping mechanism; 310, paint stripping station mounting bracket; 320, horizontal linear module; 321, first slider rail module; 322, first mounting plate; 323, first drive assembly; 330, vertical adjustment module; 331, second slider rail module; 332, motor plate; 333, grinding motor; 3331, grinding head; 334, vertical drive assembly. 340. Bearing plate; 341. Guide groove; 350. Lifting, pressing, and dust removal linkage assembly; 351. Third slider slide rail module; 352. Lifting plate; 353. Vertical drive component; 354. Upper slide seat; 355. Lower slide seat; 356. Pressing slider; 357. Pressing block; 358. Chip suction slider; 359. Chip suction bend; 400. Soldering mechanism; 410. Adjustable mounting bracket; 420. Semi-sealed chamber; 430. Flux box; 440. Solder pot; 500. Forming mechanism; 510. Vertical plate; 520. Multiple pusher assemblies; 521. First pusher assembly; 5211. First mounting bracket; 5212, First cylinder; 5213, First pusher slider slide rail module; 5214, First pusher holder; 5215, First pusher; 522, Second pusher assembly; 5221, Lifting component; 5222, Second cylinder; 5223, Second pusher slider slide rail module; 5224, Second pusher holder; 5225, Second pusher; 523, Third pusher assembly; 5231, Third mounting plate; 5232, Third pusher slider slide rail module; 5233, Third pusher holder; 5234, Third pusher; 5235, Third cylinder; 524, Fourth pusher assembly; 5241, Fourth mounting plate; 5 242. Fourth pusher slider slide rail module; 5243. Fourth pusher seat; 5244. Fourth pusher; 5245. Fourth cylinder; 530. Moving feed assembly; 531. Second mounting bracket; 532. Screw drive mechanism; 533. Moving slider slide rail module; 534. Moving plate; 535. Gripper cylinder; 536. Gripper; 540. Mandrel unloading assembly; 541. Mandrel mounting bracket; 542. Drive cylinder; 543. Mandrel; 550. Auxiliary plate; 551. First support plate; 552. Second support plate; 560. Pressing assembly; 561. Pressing cylinder; 562. Pressing head. Detailed Implementation

[0048] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0049] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0050] Example:

[0051] Please see Figures 1-16 The present invention provides a technical solution: an automatic forming machine for door-shaped coils, comprising: a cabinet 100 and a mounting plate 110 disposed on the cabinet 100, and a protective cover 120 composed of profiles and cabinet doors is provided on the outside of the cabinet 100;

[0052] A straightening mechanism 200, a paint stripping mechanism 300, a soldering mechanism 400, and a forming mechanism 500 are sequentially arranged on the mounting plate 110 along the copper wire conveying direction;

[0053] The straightening mechanism 200 includes two sets of straightening units arranged at a 90° angle and used for horizontal and vertical straightening respectively;

[0054] The paint stripping mechanism 300 includes a polishing motor 333 and a polishing head 3331 located at the output end of the polishing motor 333. The polishing head 3331 is located directly above the copper wire. The paint stripping mechanism 300 is also equipped with a linear module for driving the polishing head 3331 to perform horizontal reciprocating motion and vertical lifting motion, as well as a lifting and pressing dust removal linkage assembly 350 for pressing down and locking the copper wire during polishing.

[0055] The forming mechanism 500 includes a vertical plate 510, multiple sets of pusher assemblies 520 arranged around the copper wire processing position, a moving feed assembly 530 for pulling the copper wire to move along the conveying direction, and a mandrel unloading assembly 540; the mandrel unloading assembly 540 is configured to extend to the processing position to provide positioning support when the copper wire is bent and formed, and to retract backward to drop the formed coil after forming is completed.

[0056] Specifically, the horizontal and vertical straightening units of the straightening mechanism 200 are vertically intersecting to eliminate the stress on the copper wire in its factory-curled state, keeping the wire straight. During operation, the lifting, pressing, and dust removal linkage component 350 first presses down to fix the copper wire, then the grinding head 3331 descends and moves horizontally to remove the enamel coating from the surface of the copper wire of a specific length. Afterward, the wire passes through the soldering mechanism 400 and enters the forming mechanism 500, where it is bent around the processing center by multiple sets of pusher components 520 arranged on the vertical plate 510. The shearing and moving feed assembly 530 is responsible for providing a precise feed distance; when the copper wire enters the bending process, the mandrel ejection assembly 540 located on the back of the forming mechanism 500 extends forward to provide forming positioning support; after the bending and shearing action is completed, the mandrel ejection assembly 540 immediately retracts backward, and the formed coil product falls directly from the processing position by gravity; although the specific control system is not shown in the attached drawings, in actual implementation, this equipment is equipped with an electrical controller and alarm lights that are electrically connected to each drive motor and cylinder.

[0057] Preferably, each straightening unit of the straightening mechanism 200 includes a retainer 210, multiple adjusting sliders 220 slidably disposed within the retainer 210, straightening wheels 221 rotatably disposed on the adjusting sliders 220, and a screw adjusting assembly 230 passing through the retainer 210 and connected to the adjusting sliders 220. The outer end of the screw adjusting assembly 230 is provided with a handwheel 231 for adjusting the spacing between the straightening wheels 221, and the multiple straightening wheels 221 of the same straightening unit are staggered along the direction of the copper wire.

[0058] Specifically, the screw adjustment assembly 230 passes through the cage 210 from the outside and engages with the internal adjustment slider 220 via a threaded connection. A handwheel 231 is provided at the outer end of the screw adjustment assembly 230. Manually rotating the handwheel 231 will cause the adjustment slider 220 to slide within the cage 210, thereby adjusting the spacing of multiple straightening rollers 221 within the same unit. The straightening rollers 221 of the same straightening unit are arranged in an S-shape along the copper wire conveying direction to ensure that the copper wire is subjected to uniform pressure and bending force. If gears are used to drive multiple screws for unified adjustment in actual implementation, considering that the gears are precision components and are directly exposed and susceptible to dust, a protective shell is fitted on the outside of the screw adjustment assembly 230 to cover and protect the handwheel 231 and the gear transmission parts, extending their service life and improving operational safety.

[0059] Preferably, the paint stripping mechanism 300 includes a paint stripping station mounting frame 310, and the linear module includes a horizontal linear module 320 mounted on the paint stripping station mounting frame 310 and a vertical adjustment module 330 mounted on the output end of the horizontal linear module 320.

[0060] The horizontal linear module 320 includes a first slider rail module 321, a first mounting plate 322 slidably disposed on the first slider rail module 321, and a first driving component 323 for driving the first mounting plate 322 to slide horizontally.

[0061] The vertical adjustment module 330 includes a second slider rail module 331 disposed on the first mounting plate 322, a motor plate 332 slidably disposed on the second slider rail module 331, and a vertical drive assembly 334 for driving the motor plate 332 to move up and down along the second slider rail module 331. The grinding motor 333 is horizontally inserted and fixed on the motor plate 332.

[0062] Specifically, the paint stripping mechanism 300 includes a structurally stable paint stripping station mounting frame 310; the linear module is divided into two levels: the first level is a horizontal linear module 320 fixed on the paint stripping station mounting frame 310, which includes a first slider rail module 321 and a first mounting plate 322 slidably mounted thereon, driven by a first drive assembly 323 to slide horizontally along the copper wire direction; the second level is a vertical adjustment module 330 mounted on the first mounting plate 322; the vertical adjustment module 330 includes a vertically arranged second slider rail module... The assembly consists of a 331, a motor plate 332 slidably mounted thereon, and a vertical drive assembly 334. The grinding motor 333 is fixedly mounted on the motor plate 332 in a horizontally interlocking manner. In specific implementation, the first drive assembly 323 and the vertical drive assembly 334 adopt a motor-driven lead screw structure. In order to clearly show the main structure on the drawing, the coupling between the motor and the lead screw is omitted in the attached drawing. In actual assembly, the two are connected by a coupling, and the lead screw is equipped with a matching bearing seat and a threaded pair fixed to the slider to ensure the smoothness of the operation and avoid vibration during grinding.

[0063] Preferably, a support plate 340 is fixed on the paint stripping station mounting bracket 310;

[0064] The lifting, pressing, and dust removal linkage assembly 350 includes a third slider rail module 351 fixed on the bearing plate 340, a lifting plate 352 slidably disposed on the third slider rail module 351, and a vertical drive component 353 fixed on the paint stripping station mounting frame 310 for driving the lifting plate 352 to rise and fall.

[0065] The lifting plate 352 is horizontally spaced on its side with an upper slide block 354 and a lower slide block 355. The upper slide block 354 is provided with a sliding and lockable pressing slider 356, and the pressing slider 356 is provided with a pressing block 357 extending toward the copper wire and used to press down and fix the copper wire. The lower slide block 355 is provided with a sliding and lockable chip suction slider 358, and the chip suction slider 358 is connected to a chip suction bend 359. When the vertical drive member 353 drives the lifting plate 352 to descend, the pressing block 357 presses the copper wire and the chip suction bend 359 moves synchronously to the vicinity of the grinding position. The bearing plate 340 is provided with a guide groove 341 for the copper wire to pass through and to cooperate with the upper pressing block 357 to ensure that the force is applied during grinding.

[0066] Specifically, a support plate 340 is horizontally fixed on the paint stripping station mounting frame 310; in the lifting, pressing, and dust removal linkage assembly 350, the third slider rail module 351 is vertically fixed on the support plate 340, and the lifting plate 352 is slidably mounted on it, driven by the vertical drive component 353 fixed on the paint stripping station mounting frame 310 to move up and down; the lifting plate 352 is horizontally spaced with an upper slide block 354 and a lower slide block 355 on its side; the upper slide block 354 is equipped with a pressing slider 356 that can move back and forth in the horizontal direction and can be locked by screws, and the end of the pressing slider 356 extends out to form a downward pressing block 357; the lower slide block 355 is equipped with... Similarly, a sliding and locking chip suction slider 358 is assembled, to which a chip suction bend 359 is fixedly connected; when the vertical drive 353 drives the lifting plate 352 to descend, the pressure block 357 presses down to fix the copper wire to be stripped, and at the same time the chip suction bend 359 descends to a distance from the grinding head 3331; a guide groove 341 is opened on the bearing plate 340, and the copper wire passes through this groove. When the pressure block 357 presses down, the copper wire is firmly pressed against the bottom surface of the guide groove 341, thereby providing a reliable force base during horizontal grinding and avoiding bouncing; in addition, the vertical drive 353 is actually a cylinder, and a pneumatic triplet and solenoid valve are set on the outside of the equipment to supply air and control the cylinder.

[0067] Preferably, the soldering mechanism 400 includes an adjustable mounting bracket 410 fixed on the mounting plate 110 and a semi-sealed chamber 420 disposed on the adjustable mounting bracket 410; the semi-sealed chamber 420 has openings on both sides for copper wires to pass through and exit, and a fume vent at the top; inside the semi-sealed chamber 420, a flux box 430 and a solder pot 440 are arranged sequentially along the direction of copper wire travel.

[0068] Specifically, in the soldering mechanism 400, the adjustable mounting bracket 410 is fixed on the mounting platform 110, and a semi-sealed chamber 420 is installed above it. The semi-sealed chamber 420 has openings on both sides for copper wires to pass through and an exhaust port on the top. Inside the semi-sealed chamber 420, a flux box 430 containing flux and an electric soldering furnace 440 are arranged in sequence along the copper wire's travel path. The copper wire first picks up flux during its passage and then enters the soldering furnace 440 to complete the soldering step. The semi-sealed chamber 420 can confine the gas volatilized by the flux and the oxides floating on the surface of the soldering furnace within a certain space, and connects to the exhaust pipe outside through the exhaust port on the top to prevent harmful gases from entering the workshop environment.

[0069] Preferably, the multiple pusher assemblies 520 include a first pusher assembly 521, a second pusher assembly 522, a third pusher assembly 523, and a fourth pusher assembly 524;

[0070] The first pusher assembly 521 includes a first mounting bracket 5211 disposed on the upright plate 510, a first cylinder 5212 disposed on the first mounting bracket 5211, a first pusher slider slide rail module 5213 disposed on the upright plate 510, a first pusher seat 5214 slidably disposed on the first pusher slider slide rail module 5213, and a first pusher 5215 disposed on the first pusher seat 5214. The first pusher seat 5214 is drivenly connected to the first cylinder 5212.

[0071] The second pusher assembly 522 includes a lifting member 5221 disposed on the upright plate 510, a second cylinder 5222 disposed on the lifting member 5221, a second pusher slider slide rail module 5223 disposed on the lifting member 5221, a second pusher seat 5224 slidably disposed on the second pusher slider slide rail module 5223, and a second pusher 5225 disposed on the second pusher seat 5224. The second pusher seat 5224 is drivenly connected to the second cylinder 5222, and the second pusher assembly 522 is disposed opposite to the first pusher assembly 521.

[0072] The third pusher assembly 523 includes a third mounting plate 5231 on the upright plate 510, a third pusher slider slide rail module 5232 on the third mounting plate 5231, a third pusher seat 5233 on the third pusher slider slide rail module 5232, a third pusher 5234 on the third pusher seat 5233, and a third cylinder 5235 on the third mounting plate 5231. The third pusher seat 5233 and the third cylinder 5235 are drivenly connected.

[0073] The fourth pusher assembly 524 includes a fourth mounting plate 5241 on the vertical plate 510, a fourth pusher slider rail module 5242 on the fourth mounting plate 5241, a fourth pusher seat 5243 on the fourth pusher slider rail module 5242, a fourth pusher 5244 on the fourth pusher seat 5243, and a fourth cylinder 5245 on the fourth mounting plate 5241. The fourth pusher seat 5243 and the fourth cylinder 5245 are drivenly connected. The third pusher assembly 523 and the fourth pusher assembly 524 are located on the left and right sides of the machining position, respectively, and are obliquely arranged towards the middle machining position.

[0074] Specifically, multiple pusher assemblies 520 constitute the core shearing and bending part of the forming mechanism 500. The four pusher assemblies are specifically distributed above, below, to the left and right of the processing position; the specific action sequence is as follows:

[0075] The first pusher assembly 521 is fixed above the upright plate 510. The first mounting bracket 5211 is equipped with a first cylinder 5212. The first cylinder 5212 drives the first pusher seat 5214 and the first pusher 5215, which slide on the first pusher slider rail module 5213, to move downwards. In the wire cutting process, the copper wire is cut and a U-shaped or gate-shaped base bend is pressed out at the same time.

[0076] The second pusher assembly 522 is installed below the upright plate 510 via the lifting member 5221, and includes a second cylinder 5222, a second pusher slider rail module 5223, a second pusher seat 5224, and a second pusher 5225; after the left and right pushers complete the inward folding, the second cylinder 5222 drives the second pusher 5225 to push upward, and performs the final upward pressing and flattening operation on the inwardly folded left and right pins;

[0077] The third pusher assembly 523 and the fourth pusher assembly 524 have the same structure but are mirror-symmetrically installed on the left and right sides of the upright plate 510. The third pusher assembly 523 includes a third mounting plate 5231, a third pusher slider rail module 5232, a third pusher seat 5233, a third pusher 5234, and a third cylinder 5235. The fourth pusher assembly 524 includes a fourth mounting plate 5241, a fourth pusher slider rail module 5242, a fourth pusher seat 5243, a fourth pusher 5244, and a fourth cylinder 5245. After the first pusher assembly 521 completes the downward cutting and pressing, these two sets of oblique pusher assemblies are driven by their respective cylinders to push obliquely upward toward the middle processing position, completing the inward folding process of the pins on the left and right sides of the copper wire.

[0078] Preferably, an auxiliary plate 550 is provided on the upright plate 510 at the copper wire processing position. The auxiliary plate 550 includes a first support plate 551 and a second support plate 552 respectively provided on the wire entry side and the wire exit side of the processing position. The first support plate 551 has a guide hole for the copper wire to pass through, and the second support plate 552 has a support groove for supporting the end of the copper wire.

[0079] The forming mechanism 500 also includes a pressing component 560, which is mounted on the vertical plate 510 and located at the starting end of the copper wire entering the processing position. It includes a vertically mounted pressing cylinder 561 and a pressing head 562 located at the output end of the pressing cylinder 561. The vertical plate 510 is provided with a bearing position that cooperates with the pressing head 562. When the pressing head 562 cuts the copper wire with the push knife, it presses down to fix the copper wire and prevents the copper wire from slipping at the moment of cutting.

[0080] Specifically, an auxiliary plate 550 is provided in the copper wire processing area of ​​the upright plate 510. The auxiliary plate 550 includes a first support plate 551 on the wire inlet side and a second support plate 552 on the wire outlet side. The first support plate 551 is machined with a guide through hole, through which the copper wire is accurately inserted. The second support plate 552 is provided with a support groove, which is used to support the other end of the copper wire during forming and shearing to prevent the end from slipping off.

[0081] A pressing assembly 560 is provided in front of the copper wire just as it enters the processing position. The pressing assembly 560 includes a pressing cylinder 561 vertically mounted on a vertical plate 510 and a pressing head 562 located at the output end of the pressing cylinder 561. The vertical plate 510 is provided with a bearing position corresponding to the pressing head 562. When the first pusher assembly 521 performs the cutting action, the pressing cylinder 561 is pushed out instantly, and the pressing head 562 presses down to fix the copper wire, preventing the pulled-out copper wire from springing back or moving horizontally due to the huge shearing force at the moment of cutting. The copper wire is slid inwards; after the moving feed assembly 530 transports the copper wire to the predetermined processing position and stops, the pressing cylinder 561 is activated first, driving the pressing head 562 to press down and fix the copper wire; after confirming that the pressing head 562 is reliably pressed in place, the controller sends a command to the first pusher assembly 521 to drive the first pusher 5215 to perform cutting and gate-shaped bending actions; this sequential control logic of pressing first and then cutting can effectively avoid the copper wire that has been pulled out from springing back or sliding laterally due to the huge shearing force at the moment of cutting.

[0082] Preferably, the mandrel unloading assembly 540 includes a mandrel mounting bracket 541 located on the back of the upright plate 510 and facing the processing position, a drive cylinder 542 horizontally mounted on the mandrel mounting bracket 541, and a mandrel 543 connected to the output end of the drive cylinder 542; the upright plate 510 has a clearance hole for the mandrel 543 to pass through; when bending and forming, the drive cylinder 542 drives the mandrel 543 to pass through the clearance hole and extend into the processing position to provide internal support and positioning; after forming is completed, the mandrel 543 is pulled back so that the coil finished product can fall off by gravity.

[0083] Specifically, the mandrel mounting bracket 541 of the mandrel stripping assembly 540 is fixed to the back of the upright plate 510 and faces the machining position; a drive cylinder 542 is horizontally fixed on the mandrel mounting bracket 541; the mandrel 553 is installed at the output end of the drive cylinder 542, and the mandrel 543 can pass through the clearance hole on the upright plate 510 and extend into the machining center area where the auxiliary plate 550 is located; before the multiple pusher assemblies 520 start to operate, the drive cylinder 542 first operates to extend the mandrel 543 forward, and in the entire bending and forming process, "the first pusher 521 presses down to form and cut, the third pusher 523 and the fourth pusher 524 push in obliquely to complete the process". During the "inward folding and pin leveling" process, the coil remains extended, providing internal support and positioning for the copper wire, forming the central positioning axis for bending. When all the actions of the first pusher 521, third pusher 523, fourth pusher 524, and second pusher 522 are completed, and multiple pusher assemblies 520 retract to their original positions, the drive cylinder 542 controls the spindle 543 to quickly retract past the clearance hole. The finished coil, no longer supported by the spindle 543, can fall into the receiving groove below by its own weight. This "extending support before forming and retracting for unloading after forming" action logic is precisely controlled by the controller to achieve the cylinder solenoid valve.

[0084] Preferably, the moving feed assembly 530 includes a second mounting bracket 531 located on the back of the upright plate 510, a screw drive mechanism 532 and a moving slider rail module 533 located on the second mounting bracket 531, and a moving plate 534 connected to and driven by the screw drive mechanism 532 and the moving slider rail module 533 to slide back and forth; the upright plate 510 has an elongated clearance hole for the moving plate 534 to pass through; the end of the moving plate 534 is provided with a gripper cylinder 535, and the output end of the gripper cylinder 535 is provided with a gripper 536 for gripping copper wire and pulling the copper wire into the forming mechanism 500 under the drive of the moving plate 534.

[0085] Specifically, the moving feed assembly 530 is used to achieve precise wire drawing and feeding of the forming mechanism 500; its second mounting bracket 531 is installed on the back of the upright plate 510, and a lead screw transmission mechanism 532 and a moving slider rail module 533 are fixed inside; in actual implementation, the lead screw transmission mechanism 532 is driven by a motor to rotate the lead screw; one end of the moving plate 534 is fixedly connected to the nut seat of the lead screw and the slider of the moving slider rail module 533, and the other end passes through the elongated clearance hole of the upright plate 510 and extends to the front. Processing station; a gripper cylinder 535 is suspended at the end of the moving plate 534, and a pair of openable grippers 536 are provided at the output end of the gripper cylinder 535; during feeding, the grippers 536 close to clamp the copper wire, and then the motor drives the lead screw to rotate, forcing the moving plate 534 to move a specific distance along the moving slider rail module 533, accurately sending the copper wire into the center position of the forming mechanism 500; during unloading, the grippers 536 are released, and the moving plate 534 is reset to prepare for the next cycle of copper wire clamping action;

[0086] In the overall operation of the equipment, paint stripping and soldering are both small-scale operations. In the actual system, the cabinet 100 has a centralized control panel, and all pneumatic actuators are supplied with filtered and depressurized air by a pneumatic triplet. The dust suction bend 359 in the paint stripping mechanism 300 is connected to an external dust collection negative pressure source through an external negative pressure pipeline to ensure that paint stripping dust does not overflow. In addition, a three-color alarm light can be installed on the top or side of the cabinet 100 to trigger an alarm when the equipment is missing a wire, stuck a wire, or the air supply pressure is insufficient.

[0087] Working principle: The copper wire is first straightened horizontally and vertically by the straightening mechanism 200, and then enters the paint stripping mechanism 300. The lifting, pressing and dust removal linkage component 350 drives the pressure block 357 to cooperate with the guide groove 341 on the bearing plate 340 to press the copper wire. The grinding motor 333 drives the grinding head 3331 to descend and move horizontally to complete the grinding and paint stripping of a specific length of copper wire. At the same time, the dust suction bend 359 simultaneously sucks up the grinding dust. The copper wire that has been stripped of paint then enters the semi-sealed chamber 420 of the soldering mechanism 400, and passes through the flux box 430 and the tin furnace 440 in sequence to complete the fluxing and tinning. The processed copper wire enters the forming mechanism 500. The gripper 536 of the moving feeding component 530 pulls the copper wire for precise positioning. The pressing head 562 of the pressing component 560 first presses down to fix the copper wire. To prevent displacement during cutting, the mandrel 543 of the mandrel unloading assembly 540 extends forward and passes through the auxiliary plate 550 to provide internal bending support. Then, the first pusher assembly 521 presses down to complete the wire cutting and gate-shaped bending process. Next, the third pusher assembly 523 and the fourth pusher assembly 524 push in obliquely from the left and right sides to complete the inward bending process of the copper wire leads. Finally, the second pusher assembly 522 pushes upward to complete the lead flattening. After all forming and flattening actions are completed, multiple sets of pusher assemblies 520 return to their original positions, and the mandrel unloading assembly 540 drives the mandrel 543 to quickly retract backward. The formed coil falls due to gravity after losing its internal support. The controller and pneumatic triplet (not shown in the attached diagram) are responsible for controlling the cylinder and motor to operate in the above sequence to ensure the equipment operates in a cyclical manner.

[0088] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. An automatic forming machine for portal coils, characterized in that, include: The cabinet (100) and the mounting plate (110) disposed on the cabinet (100) are provided with a protective cover (120) consisting of profiles and cabinet doors on the outside of the cabinet (100). A straightening mechanism (200), a paint stripping mechanism (300), a soldering mechanism (400) and a forming mechanism (500) are sequentially arranged on the mounting plate (110) along the copper wire conveying direction. The straightening mechanism (200) includes two sets of straightening units arranged at a 90° angle and used for horizontal and vertical straightening respectively; The paint stripping mechanism (300) includes a polishing motor (333) and a polishing head (3331) located at the output end of the polishing motor (333). The polishing head (3331) is located directly above the copper wire. The paint stripping mechanism (300) is also equipped with a linear module for driving the polishing head (3331) to perform horizontal reciprocating motion and vertical lifting motion, as well as a lifting and pressing dust removal linkage assembly (350) for pressing down and locking the copper wire during polishing. The forming mechanism (500) includes a vertical plate (510), multiple sets of pusher assemblies (520) arranged around the copper wire processing position, a moving feed assembly (530) for pulling the copper wire to move along the conveying direction, and a mandrel unloading assembly (540); the mandrel unloading assembly (540) is configured to extend to the processing position to provide positioning support when the copper wire is bent and formed, and to retract backward to drop the formed coil after forming is completed.

2. The automatic forming machine for portal coils according to claim 1, characterized in that: Each straightening unit of the straightening mechanism (200) includes a retainer (210), multiple adjusting sliders (220) slidably disposed within the retainer (210), straightening wheels (221) rotatably disposed on the adjusting sliders (220), and a screw adjusting assembly (230) that passes through the retainer (210) and is connected to the adjusting sliders (220). The outer end of the screw adjusting assembly (230) is provided with a handwheel (231) for adjusting the spacing between the straightening wheels (221), and the multiple straightening wheels (221) of the same straightening unit are staggered along the direction of the copper wire.

3. The automatic forming machine for portal coils according to claim 1, characterized in that: The paint stripping mechanism (300) includes a paint stripping station mounting frame (310), and the linear module includes a horizontal linear module (320) mounted on the paint stripping station mounting frame (310) and a vertical adjustment module (330) mounted at the output end of the horizontal linear module (320). The horizontal linear module (320) includes a first slider rail module (321), a first mounting plate (322) slidably disposed on the first slider rail module (321), and a first driving component (323) for driving the first mounting plate (322) to slide horizontally. The vertical adjustment module (330) includes a second slider rail module (331) disposed on the first mounting plate (322), a motor plate (332) slidably disposed on the second slider rail module (331), and a vertical drive assembly (334) for driving the motor plate (332) to move up and down along the second slider rail module (331). The grinding motor (333) is horizontally inserted and fixed on the motor plate (332).

4. The automatic forming machine for portal coils according to claim 3, characterized in that: A bearing plate (340) is fixed on the paint stripping station mounting frame (310); The lifting, pressing, and dust removal linkage assembly (350) includes a third slider rail module (351) fixed on the bearing plate (340), a lifting plate (352) slidably disposed on the third slider rail module (351), and a vertical drive component (353) fixed on the paint stripping station mounting frame (310) for driving the lifting plate (352) to rise and fall. The lifting plate (352) is horizontally spaced on its side by an upper slide block (354) and a lower slide block (355); the upper slide block (354) is provided with a sliding and lockable pressing slider (356), and the pressing slider (356) is provided with a pressing block (357) extending toward the copper wire and used to press down and fix the copper wire; the lower slide block (355) is provided with a sliding and lockable chip suction slider (358), and the chip suction slider (358) is connected to a chip suction bend (359); when the vertical drive (353) drives the lifting plate (352) to descend, the pressing block (357) presses the copper wire and the chip suction bend (359) moves synchronously to the vicinity of the grinding position, and the bearing plate (340) is provided with a guide groove (341) for the copper wire to pass through and to cooperate with the upper pressing block (357) to be stressed during grinding.

5. The automatic forming machine for portal coils according to claim 1, characterized in that: The soldering mechanism (400) includes an adjustable mounting bracket (410) fixed on the mounting platform (110) and a semi-sealed chamber (420) provided on the adjustable mounting bracket (410); the semi-sealed chamber (420) has openings on both sides for copper wires to pass through and exit, and a fume vent at the top; inside the semi-sealed chamber (420) along the direction of copper wire travel, a flux box (430) and a solder pot (440) are arranged in sequence.

6. The automatic forming machine for portal coils according to claim 1, characterized in that: The multiple pusher assemblies (520) include a first pusher assembly (521), a second pusher assembly (522), a third pusher assembly (523), and a fourth pusher assembly (524). The first pusher assembly (521) includes a first mounting bracket (5211) disposed on the upright plate (510), a first cylinder (5212) disposed on the first mounting bracket (5211), a first pusher slider rail module (5213) disposed on the upright plate (510), a first pusher seat (5214) slidably disposed on the first pusher slider rail module (5213), and a first pusher (5215) disposed on the first pusher seat (5214). The first pusher seat (5214) is drivenly connected to the first cylinder (5212). The second pusher assembly (522) includes a lifting member (5221) disposed on the upright plate (510), a second cylinder (5222) disposed on the lifting member (5221), a second pusher slider slide rail module (5223) disposed on the lifting member (5221), a second pusher seat (5224) slidably disposed on the second pusher slider slide rail module (5223), and a second pusher (5225) disposed on the second pusher seat (5224). The second pusher seat (5224) is drivenly connected to the second cylinder (5222), and the second pusher assembly (522) is disposed opposite to the first pusher assembly (521). The third pusher assembly (523) includes a third mounting plate (5231) on the upright plate (510), a third pusher slider rail module (5232) on the third mounting plate (5231), a third pusher seat (5233) on the third pusher slider rail module (5232), a third pusher (5234) on the third pusher seat (5233), and a third cylinder (5235) on the third mounting plate (5231). The third pusher seat (5233) is drivenly connected to the third cylinder (5235). The fourth pusher assembly (524) includes a fourth mounting plate (5241) on the vertical plate (510), a fourth pusher slider rail module (5242) on the fourth mounting plate (5241), a fourth pusher seat (5243) on the fourth pusher slider rail module (5242), a fourth pusher (5244) on the fourth pusher seat (5243), and a fourth cylinder (5245) on the fourth mounting plate (5241). The fourth pusher seat (5243) is drivenly connected to the fourth cylinder (5245). The third pusher assembly (523) and the fourth pusher assembly (524) are located on the left and right sides of the machining position, respectively, and are obliquely arranged towards the middle machining position.

7. The automatic forming machine for portal coils according to claim 1, characterized in that: An auxiliary plate (550) is provided on the upright plate (510) at the copper wire processing position. The auxiliary plate (550) includes a first support plate (551) and a second support plate (552) respectively provided on the wire entry side and the wire exit side of the processing position. The first support plate (551) has a guide hole for the copper wire to pass through, and the second support plate (552) has a support groove for supporting the end of the copper wire. The forming mechanism (500) further includes a pressing component (560), which is disposed on the upright plate (510) and located at the starting end of the copper wire entering the processing position. It includes a vertically installed pressing cylinder (561) and a pressing head (562) disposed at the output end of the pressing cylinder (561). The upright plate (510) is provided with a bearing position that cooperates with the pressing head (562). When the pressing head (562) cuts the copper wire with the push knife, it presses down to fix the copper wire and prevents the copper wire from slipping at the moment of cutting.

8. The automatic forming machine for portal coils according to claim 1, characterized in that: The mandrel unloading assembly (540) includes a mandrel mounting bracket (541) located on the back of the upright plate (510) and facing the processing position, a drive cylinder (542) horizontally mounted on the mandrel mounting bracket (541), and a mandrel (543) connected to the output end of the drive cylinder (542). The upright plate (510) has a clearance hole for the mandrel (543) to pass through. When bending and forming, the drive cylinder (542) drives the mandrel (543) to pass through the clearance hole and extend into the processing position to provide internal support and positioning. After forming, the mandrel (543) is pulled back so that the coil product can fall off by gravity.

9. The automatic forming machine for portal coils according to claim 1, characterized in that: The moving feed assembly (530) includes a second mounting bracket (531) on the back of the upright plate (510), a screw drive mechanism (532) and a moving slider rail module (533) on the second mounting bracket (531), and a moving plate (534) connected to and driven by the screw drive mechanism (532) and the moving slider rail module (533) to slide back and forth. The upright plate (510) has an elongated clearance hole for the moving plate (534) to pass through. The end of the moving plate (534) is provided with a gripper cylinder (535), and the output end of the gripper cylinder (535) is provided with a gripper (536) for gripping copper wire and pulling the copper wire into the forming mechanism (500) under the drive of the moving plate (534).

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