Flat copper wire winding forming device and process

Abstract

The present application relates to the technical field of flat copper wire processing, and discloses a flat copper wire winding forming device and process, the device comprising a winding host, the winding host being provided with a rotating main disc and a winding die assembly; the winding die assembly comprising a radial guide rod, the radial guide rod being installed on the rotating main disc, the radial guide rod being provided with a first winding assembly and a second winding assembly, the first winding assembly comprising a first mounting seat and a winding die seat provided on the first mounting seat, the second winding assembly comprising a second mounting seat and a winding support shaft provided on the second mounting seat, at least one lateral pressing assembly for preventing the coil from falling off being arranged between the first winding assembly and the second winding assembly; wherein the first winding assembly and / or the second winding assembly is provided with a demolding mechanism for separating the flat copper wire after winding from the winding die assembly. The present application solves the problem of the flat copper wire winding forming being stuck, realizes smooth demolding, and improves the quality of finished products.

Description

Technical Field

[0001] This application relates to the technical field of flat copper wire processing, and in particular to a flat copper wire winding forming apparatus and process. Background Technology

[0002] In the field of motor stator manufacturing, the stator, as a core component, directly affects the overall performance of the motor. Stator coils are typically processed using a winding forming device, which uses a rotating main disc to drive a mold assembly to wind the wire into a closed coil along a predetermined trajectory.

[0003] However, for stators using waist-shaped coils, their manufacturing quality and production efficiency directly determine the performance and manufacturing cost of the motor. Existing winding and forming devices for flat copper wires have the following shortcomings: First, after winding, the coil is tightly gripped to the support structure due to the springback stress of the wire. Operators can only rely on external force to forcibly pull out the coil, which is not only difficult to operate, but also easily damages the coil insulation layer. Second, existing methods for clamping wire ends mostly rely on manual operation, and the clamping force is not easy to control, which can easily lead to unstable clamping force during coil winding, affecting the forming accuracy.

[0004] Therefore, the need for a flat copper wire winding forming device to achieve smooth demolding and efficient production of coils is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0005] To overcome the above problems, this application provides a flat copper wire winding forming apparatus and process.

[0006] A flat copper wire winding forming device includes a winding host, wherein the winding host is provided with a rotating main disk and a winding mold assembly mounted on the rotating main disk; The winding mold assembly includes a radial guide rod, which is mounted on the rotating main disk. A first winding assembly and a second winding assembly are disposed on the radial guide rod. The first winding assembly includes a first mounting base and a winding mold base disposed on the first mounting base. The second winding assembly includes a second mounting base and a winding support shaft disposed on the second mounting base. At least one lateral clamping assembly for preventing the coil from falling off is disposed between the first winding assembly and the second winding assembly. The first winding assembly and / or the second winding assembly are provided with a demolding mechanism for the flat copper wire to be released from the winding mold assembly after winding.

[0007] By adopting the above technical solution, the winding host drives the rotating main disk to rotate, which in turn drives the radial guide rod and the winding mold assembly to rotate synchronously, providing stable power and precise trajectory for the flat copper wire winding and forming. The first winding assembly and the second winding assembly are arranged opposite to each other on the radial guide rod, which together limit the winding trajectory of the flat copper wire and ensure the forming accuracy of the coil. The lateral clamping assembly is set between the two assemblies, which clamps the starting end of the flat copper wire during the winding process, effectively preventing the coil from falling off and ensuring the stability of the winding process. The demolding mechanism is set on the first winding assembly and / or the second winding assembly. After the winding is completed, it can actively change the relative position between the assemblies, so that the coil can be released from the mold assembly. This solves the problem in the prior art that the coil is stuck on the support structure due to springback stress and is difficult to remove. It avoids damage to the coil caused by forced dragging and improves the convenience of demolding operation and product quality.

[0008] Furthermore, the demolding mechanism includes a demolding slide and a demolding drive component. The demolding slide and the demolding drive component are disposed on the second mounting base. The winding support shaft is installed in the demolding slide. The demolding drive component is connected to the winding support shaft and is used to drive the winding support shaft to move closer to or away from the first winding assembly along the demolding slide.

[0009] By adopting the above technical solution, the demolding mechanism includes a demolding slide and a demolding drive component. The demolding drive component drives the winding support shaft to translate along the demolding slide towards the first winding assembly, thereby actively eliminating the clamping force between the coil and the support shaft, achieving controlled release of the coil, and avoiding damage caused by forced dragging. Furthermore, the demolding slide precisely guides the movement path of the support shaft, preventing deviation or jamming during the demolding process and improving the smoothness of demolding. In addition, the demolding mechanism is integrated with the second mounting base, simplifying the equipment layout and ensuring the consistency and repeatability of each demolding action.

[0010] Furthermore, the demolding drive includes a stepper motor and a lead screw. The stepper motor is mounted on the second mounting base, the lead screw is connected to the output shaft of the stepper motor, and the nut of the lead screw is connected to the winding support shaft. The stepper motor drives the lead screw to rotate, causing the nut to drive the winding support shaft to translate along the demolding groove.

[0011] By adopting the above technical solution, a stepper motor and a lead screw are used as the demolding drive components. The pulse control of the stepper motor is used to achieve high-precision linear displacement of the winding support shaft, which solves the problem of difficult position control during demolding. The self-locking characteristics of the stepper motor and the lead screw can maintain the position of the support shaft after power failure, preventing coil springback or accidental slippage during demolding. At the same time, this drive method supports extremely low-speed and stable motion, providing a hardware foundation for micro-displacement control in the step-by-step demolding process, and significantly improving the stability and controllability of demolding.

[0012] Furthermore, an insulating pad is fitted on the outer surface of the winding support shaft, and the insulating pad is any one of nylon sleeve, Teflon sleeve, polyoxymethylene sleeve, or polyetheretherketone sleeve.

[0013] By adopting the above technical solution, a low-friction insulating pad, such as a nylon sleeve, Teflon sleeve, polyoxymethylene sleeve, or polyetheretherketone sleeve, is applied to the outer surface of the winding support shaft. This effectively reduces the sliding friction coefficient between the coil and the winding support shaft during demolding, reduces demolding resistance, and prevents the coil insulation layer from being scratched or worn due to excessive friction. At the same time, the insulating pad has good insulation properties, electrically isolating the flat copper wire from the winding support shaft and preventing short circuits caused by insulation damage, further ensuring the coil molding quality and safety in use. In addition, the pad has good self-lubricating and wear-resistant properties, extending the service life of the winding support shaft.

[0014] Furthermore, the first mounting base and the second mounting base are slidably mounted on the radial guide rod via the linear drive mechanism.

[0015] By adopting the above technical solution, the linear drive mechanism slidably mounts the first mounting base and the second mounting base on the radial guide rod, realizing flexible adjustment of the distance between the winding mold base and the winding support shaft. This allows the device to adapt to flat copper wire coils of different widths, solving the problem that the traditional fixed-gap structure is difficult to adapt to coils of various specifications, and improving the versatility and production flexibility of the equipment.

[0016] Furthermore, the linear drive mechanism includes a geared motor mounted on the first mounting base or the second mounting base, a gear mounted on the output shaft of the geared motor, and a sliding guide rail fixed on the radial guide rod. The sliding guide rail is provided with a rack that meshes with the gear. The geared motor drives the gear to mesh with the rack, causing the first mounting base or the second mounting base to move axially along the radial guide rod.

[0017] By adopting the above technical solution, the geared motor drives the gear to rotate, and the gear meshes with the racks on both sides of the sliding guide rail, converting the rotational motion into linear motion. This drives the first or second mounting seat to move axially along the radial guide rod, improving the smoothness and positioning accuracy of the sliding process. It also enables flexible adjustment of the distance between the winding mold seat and the winding support shaft, allowing the device to adapt to the production needs of coils of different widths. In addition, the meshing of the gear and rack has a self-locking characteristic, maintaining the stable position of the mounting seat after power failure, preventing the distance drift caused by vibration during winding, ensuring the dimensional consistency of the coil forming, and improving the versatility and production reliability of the equipment.

[0018] Furthermore, the lateral clamping assembly includes a fixed support block, a clamping plate, and a clamping drive. The fixed support block is mounted on the radial guide rod, and the clamping drive is mounted inside the fixed support block. The fixed support block has a telescopic hole, and the push rod of the clamping drive passes through the telescopic hole and connects to the clamping plate, which drives the clamping plate to reciprocate along the axial direction through the telescopic hole to clamp or release the flat copper wire.

[0019] By adopting the above technical solution, the clamping drive is installed inside the fixed support block, and a telescopic hole is opened on the fixed support block. The push rod of the clamping drive passes through the telescopic hole and connects to the clamping plate, realizing the reciprocating movement of the clamping plate along the axial direction. This structure hides the drive inside the fixed support block, making the overall layout of the equipment more compact and avoiding interference between the external drive and the flat copper wire or mold during the winding process, thus improving the safety of equipment operation. The clamping drive directly drives the clamping plate to clamp or release the flat copper wire. The clamping force transmission path is short, the action response is rapid, and the clamping force can be precisely adjusted by controlling the output parameters of the drive, so that the flat copper wire is stably clamped and not easy to slip during the winding process. At the same time, it avoids damage to the surface insulation layer of the flat copper wire due to excessive clamping force, improving the stability of the winding process and the product yield.

[0020] Furthermore, an elastic buffer layer is provided on the clamping surface of the clamping plate and the fixed support block to prevent damage to the insulation layer on the surface of the flat copper wire during clamping.

[0021] By adopting the above technical solution, an elastic buffer layer is set on the clamping surface of the clamping plate and the fixed support block. When clamping the flat copper wire, the buffer layer disperses the clamping force through elastic deformation, avoids excessive local pressure, effectively prevents damage to the insulation layer on the surface of the flat copper wire during the clamping process, and protects the forming quality of the flat copper wire.

[0022] This invention also provides a flat copper wire winding forming process, which is implemented using the flat copper wire winding forming device described above, and includes the following steps: Step S1: Based on the preset coil width, drive the first winding assembly and the second winding assembly to move relative to each other along the radial guide rod, and adjust the distance between the winding mold seat and the winding support shaft to the preset width; Step S2: Place the starting end of the flat copper wire between the clamping plate and the fixed support block of the lateral clamping assembly, and drive the clamping plate to approach the fixed support block through the electric drive component to clamp the flat copper wire. Step S3: Start the rotating main disk to wind the flat copper wire into a closed waist-shaped coil, and stop after winding to the preset number of turns; Step S4: Drive the clamping plate away from the fixed support block using an electric drive unit to release the flat copper wire; Step S5: Activate the demolding drive to drive the winding support shaft to translate along the demolding slide towards the first winding assembly, so that the coil is disengaged from the winding support shaft; Step S6: Remove the finished coil.

[0023] By adopting the above technical solution, a flat copper wire winding forming equipment has completed the entire process flow of width adjustment, clamping, winding, release, demolding, and part removal, realizing automated production of flat copper wire winding forming. The process first adjusts the distance between the first and second winding assemblies to adapt the device to the production needs of coils of different specifications. Then, the combination of electric clamping and rotary winding ensures stable clamping and precise forming of the flat copper wire during the winding process. After winding, the connection between electric release and translational demolding allows the coil to smoothly detach from the support shaft, avoiding insulation damage caused by forced dragging. The entire process is tightly integrated and operates smoothly, effectively ensuring coil forming quality and product consistency while improving production efficiency.

[0024] Furthermore, in step S5, the translation process of the winding support shaft includes: Step S51: Drive the winding support shaft to translate by 0.1-0.5mm to break the static friction lock between the coil and the winding support shaft, but the coil and the winding support shaft are not completely separated. Step S52: After the coil is released from its locked state, continue to drive the winding support shaft to translate to the preset displacement, so that the coil is completely separated from the winding support shaft.

[0025] By adopting the above technical solution, a step-by-step translation strategy is used during the demolding process. First, the winding support shaft is driven to translate a tiny distance of 0.1-0.5mm. This micro-motion breaks the static friction lock between the coil and the support shaft, at which point the coil is not yet completely detached. After the lock is released, the translation continues to the preset displacement, allowing the coil to completely detach from the support shaft. This step-by-step method of breaking static friction with micro-motion followed by translation demolding effectively avoids the impact and pulling that may occur with traditional one-time rapid demolding, reduces the risk of coil deformation or insulation damage during demolding, and ensures the smoothness and controllability of the demolding action, thereby improving the demolding success rate and product yield.

[0026] In summary, this application includes at least the following beneficial technical effects: (1) By setting up a demolding mechanism, the winding support shaft is moved towards the first winding assembly after the winding is completed, which actively eliminates the lock-up state between the coil and the support shaft. This solves the problem that the coil is difficult to remove under the traditional fixed support shaft structure and avoids damage to the coil insulation layer caused by forced dragging. Furthermore, the demolding mechanism adopts a step-by-step translation demolding process, first slightly moving to destroy static friction and then continuing to translate until complete separation, which effectively reduces the impact and pulling during the demolding process and further ensures the forming quality of the coil and the product yield.

[0027] (2) This application uses a linear drive mechanism to slidably mount the first mounting base and the second mounting base on the radial guide rod, thereby realizing flexible adjustment of the distance between the winding mold base and the winding support shaft, enabling the device to adapt to the production needs of coils of different widths, and improving the versatility and production flexibility of the equipment; at the same time, the self-locking characteristic of the gear and double rack meshing ensures the stability of the mounting base position during the winding process, ensuring the dimensional consistency of the coil forming.

[0028] (3) By hiding the clamping drive inside the fixed support block and using an elastic buffer layer, this application achieves stable clamping and release of flat copper wire, avoids damage to the insulation layer of flat copper wire during clamping, and ensures the stability of the winding process and the product yield. Attached Figure Description

[0029] Figure 1 This is a first structural schematic diagram of a flat copper wire winding forming device provided in Embodiment 1 of the present invention; Figure 2 This is a second structural schematic diagram of a flat copper wire winding forming device provided in Embodiment 1 of the present invention; Figure 3 This is an enlarged schematic diagram of structure A of a flat copper wire winding forming device provided in Embodiment 1 of the present invention; Figure 4 This is a third structural schematic diagram of a flat copper wire winding forming device provided in Embodiment 1 of the present invention; Figure 5 This is an enlarged schematic diagram of structure B of a flat copper wire winding forming device provided in Embodiment 1 of the present invention; Figure 6 This is an enlarged schematic diagram of the C structure of a flat copper wire winding forming device provided in Embodiment 1 of the present invention.

[0030] Explanation of reference numerals in the attached figures: 1. Winding main unit; 2. Rotary main disk; 3. Winding mold assembly; 31. Radial guide rod; 32. First winding assembly; 321. First mounting base; 322. Winding mold base; 33. Second winding assembly; 331. Second mounting base; 332. Winding support shaft; 4. Linear drive mechanism; 41. Gear motor; 42. Sliding guide rail; 421. Rack; 43. Rotation locking component; 5. Lateral clamping assembly; 51. Fixed support block; 52. Clamping plate; 6. Demolding mechanism; 61. Demolding groove; 62. Demolding drive component; 621. Stepper motor; 622. Lead screw. Detailed Implementation

[0031] The following combination Figure 1-6 The technical solutions in the embodiments of the present invention will be described in detail.

[0032] Example 1 See Figure 1 This invention provides a flat copper wire winding forming device, including a winding host 1, a rotating main disk 2 and a winding mold assembly 3 mounted on the rotating main disk 2. The winding host 1 is used to drive the rotating main disk to rotate, so that the winding mold assembly 3 rotates to realize the winding forming of flat copper wire.

[0033] The winding mold assembly 3 includes a radial guide rod 31, which is mounted on the rotating main disk 2. A first winding assembly 32 and a second winding assembly 33 are disposed on the radial guide rod 31. The first winding assembly 32 includes a first mounting base 321 and a winding mold base 322 disposed on the first mounting base 321. The second winding assembly 33 includes a second mounting base 331 and a winding support shaft 332 disposed on the second mounting base 331. The first winding assembly 32 and the second winding assembly 33 are arranged opposite to each other on the radial guide rod 31, which together define the winding contour of the flat copper wire, so that the flat copper wire is wound along the contour when the winding host 1 drives the rotating main disk 2 to rotate.

[0034] See Figure 2-3 In order to adjust the distance between the winding mold seat 322 and the winding support shaft 332 to accommodate coils of different widths, the first mounting seat 321 and the second mounting seat 331 are slidably mounted on the radial guide rod 31 through the linear drive mechanism 4.

[0035] Specifically, the linear drive mechanism 4 includes a geared motor 41 mounted on a first mounting base 321 and a second mounting base 331 respectively. A gear is mounted on the output shaft of the geared motor 41, and a sliding guide rail 42 is fixedly mounted on the radial guide rod 31. A rack 421 that meshes with the gear is arranged along the length direction inside the sliding guide rail 42. When the geared motor 41 drives the gear to rotate, the gear meshes with the rack 421, which can drive the corresponding mounting base to translate axially along the radial guide rod 31, thereby realizing flexible adjustment of the spacing.

[0036] To improve the stability of the winding process, the first mounting base 321 and the second mounting base 331 are also provided with a rotation locking component 43. The rotation locking component 43 is used to lock the relative position of the mounting base and the radial guide rod 31 after the mounting base slides into place, to prevent the mounting base from rotating or swaying due to force during the winding process, and to ensure the positional accuracy and dimensional consistency during the coil forming process. At the same time, the gear and rack 421 have a self-locking characteristic when meshing, and can maintain the axial position of the mounting base on the radial guide rod 31 after power is cut off, forming a double lock together with the rotation locking component 43.

[0037] As an optional implementation, the rotating locking member 43 can be an electrically driven locking pin. After the first mounting base 321 and the second mounting base 331 are moved into place, the locking pin extends and inserts into the locking hole corresponding to the radial guide rod 31 to achieve position locking. The structure is simple and reliable, and the locking action responds quickly.

[0038] In order to clamp the starting end of the flat copper wire at the beginning of winding and to prevent the coil from falling off during the winding process, two lateral clamping components 5 are also provided on the radial guide rod 31, and the two lateral clamping components 5 are located between the first winding assembly 32 and the second winding assembly 33.

[0039] Specifically, the lateral clamping assembly 5 includes a fixed support block 51, a clamping plate 52, and a clamping drive. The fixed support block 51 is mounted on the radial guide rod 31, and the clamping drive is mounted inside the fixed support block 51. The fixed support block 51 has a telescopic hole, and the push rod of the clamping drive passes through the telescopic hole and connects to the clamping plate 52. The clamping drive is used to drive the clamping plate 52 to reciprocate along the axial direction to clamp or release the flat copper wire.

[0040] In this embodiment, the clamping drive is a miniature electric push rod. When it is necessary to clamp the flat copper wire, the clamping drive drives the clamping plate 52 to retract, so that the clamping plate 52 is close to the fixed support block 51, clamping and fixing the starting end of the flat copper wire; when the winding is completed and it is necessary to release the flat copper wire, the clamping drive drives the clamping plate 52 to extend, so that the clamping plate 52 is away from the fixed support block 51, releasing the flat copper wire.

[0041] As an optional implementation, the clamping plate 52 is threadedly connected to the end of the push rod of the clamping drive. When clamping the flat copper wire, the clamping plate 52 is locked in place with the push rod of the clamping drive, and the clamping plate 52 maintains a vertical clamping posture. After releasing the flat copper wire, the clamping plate 52 can rotate freely. The operator can manually rotate the clamping plate 52 90 degrees to a horizontal position for easy handling of the flat copper wire. Before winding, the operator manually rotates the clamping plate 52 back to a vertical position, the push rod extends again, and the threaded section locks in place with the internal thread, completing the reset.

[0042] To prevent excessive local pressure from damaging the insulation layer on the surface of the flat copper wire, an elastic buffer layer is provided on the clamping surface of the clamping plate 52 and the fixed support block 51 to prevent damage to the insulation layer on the surface of the flat copper wire during clamping.

[0043] As an optional implementation, the elastic cushioning layer can be any one of a rubber pad, a polyurethane pad, a silicone pad, or a Teflon pad.

[0044] In order to facilitate the smooth removal of the coil from the winding support shaft 332 after winding is completed and to avoid damage caused by forced dragging, a demolding mechanism 6 is provided on the second mounting base 331.

[0045] Specifically, the demolding mechanism 6 includes a demolding slide 61 and a demolding drive 62. The demolding slide 61 is formed on the second mounting base 331. The demolding drive 62 is connected to the winding support shaft 332, and the winding support shaft 332 is slidably installed in the demolding slide 61. The demolding drive 62 can drive the winding support shaft 332 to translate along the demolding slide 61.

[0046] In this embodiment, the demolding drive 62 consists of a stepper motor 621 and a lead screw 622. The stepper motor 621 is mounted on the second mounting base 331, and the lead screw 622 is connected to the output shaft of the stepper motor 621. The nut of the lead screw 622 is fixedly connected to the winding support shaft 332. The stepper motor 621 drives the lead screw 622 to rotate, converting the rotational motion into linear motion, so that the nut drives the winding support shaft 332 to translate along the demolding groove 61 toward the first winding assembly 32.

[0047] To further reduce frictional damage during demolding and to achieve electrical isolation, an insulating pad is fitted on the outer surface of the winding support shaft 332.

[0048] As an optional implementation, the insulating pad is any one of nylon sleeve, Teflon sleeve, polyoxymethylene sleeve or polyetheretherketone sleeve, and is fitted onto the outer wall of the winding support shaft 332.

[0049] In this embodiment, the insulating pad is preferably a nylon sleeve, which has good self-lubricating and wear-resistant properties. It can effectively reduce the sliding friction coefficient between the coil and the winding support shaft 332 during demolding, reduce demolding resistance, and prevent the coil insulation layer from being scratched or worn due to friction. At the same time, as an insulating material, the nylon sleeve can electrically isolate the flat copper wire from the winding support shaft 332, prevent the risk of short circuit caused by insulation layer damage, and ensure the molding quality and safety of the coil.

[0050] After the winding is completed, the demolding drive 62 drives the winding support shaft 332 to translate towards the first winding assembly 32. This translation process is controlled in steps: first, the winding support shaft 332 is driven to translate a small distance to break the static friction lock between the coil and the winding support shaft 332. After the lock is released, the translation continues to the preset displacement, so that the coil is completely detached from the winding support shaft 332, thereby achieving smooth detachment of the coil.

[0051] In addition, the winding host 1 is equipped with a controller, which is electrically connected to the drive motor of the rotating main disk 2, the reduction motor 41 of the linear drive mechanism 4, the clamping drive component of the lateral clamping assembly 5, the stepper motor 621 of the demolding mechanism 6, and the drive motor of the rotating main disk 2. The controller is used to control the action sequence and motion parameters of each execution component according to the preset process parameters.

[0052] Specifically, the controller sends start / stop commands to the drive motor of the rotating main disk 2, forward / reverse commands to the geared motor 41, clamping / releasing commands to the clamping drive component, and pulse control commands to the stepper motor 621 through the above electrical connection, so as to realize the full-process automated control.

[0053] Example 2 Example 2 provides a flat copper wire winding forming process, which is implemented using a flat copper wire winding forming device as described in Example 1, and includes the following steps: Step S1: Based on the preset coil width, drive the first winding assembly 32 and the second winding assembly 33 to move relative to each other along the radial guide rod 31, and adjust the distance between the winding mold seat 322 and the winding support shaft 332 to the preset width.

[0054] Step S2: Place the starting end of the flat copper wire between the clamping plate 52 and the fixed support block 51 of the lateral clamping assembly 5, and drive the clamping plate 52 to approach the fixed support block 51 through the clamping drive component to clamp the flat copper wire.

[0055] Step S3: Start rotating the main disk 2 to wind the flat copper wire into a closed waist-shaped coil, and stop after winding to the preset number of turns.

[0056] Step S4: Drive the clamping plate 52 away from the fixed support block 51 by the clamping drive component to release the flat copper wire.

[0057] Step S5: Start the demolding drive 62, drive the winding support shaft 332 to move along the demolding slide 61 toward the first winding assembly 32, so that the coil is disengaged from the winding support shaft 332.

[0058] Step S6: Remove the finished coil.

[0059] Understandably, during the winding operation, the external wire feeding machine releases the flat copper wire at a uniform speed and maintains a constant tension, then feeds it to the winding mold assembly 3 for winding.

[0060] To reduce impact damage during demolding and ensure smooth coil release, the translation process of the winding support shaft 332 in step S5 is controlled in stages: Step S51: Drive the winding support shaft 332 to translate by 0.1-0.5mm to break the static friction lock between the coil and the winding support shaft 332. At this time, the coil and the winding support shaft 332 are still not completely separated.

[0061] Step S52: After the coil is released from its locked state, continue to drive the winding support shaft 332 to translate to the preset displacement, so that the coil is completely separated from the winding support shaft 332.

[0062] As an optional implementation, a pause time of 0.5-2 seconds can be set between steps S51 and S52 to allow the coil stress to be fully released before proceeding to the second translation step, in order to further reduce the risk of impact and deformation during the demolding process.

[0063] Furthermore, after the finished coil is removed in step S6, the controller controls the stepper motor 621 of the demolding mechanism 6 to rotate in the opposite direction, driving the winding support shaft 332 to move in the opposite direction along the demolding slide 61 until the winding support shaft 332 is reset to the initial position, preparing for the next winding operation.

[0064] In this embodiment, the above steps are automatically executed by the controller according to preset process parameters. The controller is electrically connected to the drive motors of the linear drive mechanism 4, the lateral clamping assembly 5, the demolding mechanism 6, and the rotating main disk 2. The controller controls the action sequence and time interval of each execution component according to preset timing logic to ensure seamless connection between each step: In step S1, the controller first controls the linear drive mechanism 4 to complete the width adjustment action. After detecting the signal that the first mounting base 321 and the second mounting base 331 have moved into place, it issues a locking command to lock the rotating locking member 43; In step S2, the controller controls the lateral clamping assembly 5 to clamp the flat copper wire and continuously monitors whether the clamping force reaches the required level. Once the preset threshold is reached and the clamping is confirmed to be in place, step S3 is allowed. In step S3, the controller controls the rotating main disk 2 to start winding and monitors the number of turns in real time during the winding process. Once the preset number of turns is reached, a stop command is issued immediately. In step S4, the controller controls the lateral clamping component 5 to release the flat copper wire and sets a delay of 0.5-2 seconds to ensure that the flat copper wire is completely released before proceeding to step S5. In step S5, the controller controls the demolding mechanism 6 to perform step-by-step demolding. First, a first-step micro-motion command is issued. After the displacement signal is detected, the process pauses for 0.5-1 seconds and then a second-step translation command is issued, so that the coil can be smoothly released under controlled conditions, thereby achieving fully automated control of the entire process.

[0065] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A flat copper wire winding and forming device, characterized in that: It includes a winding host (1), which is provided with a rotating main disk (2) and a winding mold assembly (3) mounted on the rotating main disk (2); The winding mold assembly (3) includes a radial guide rod (31) mounted on the rotating main disk (2). A first winding assembly (32) and a second winding assembly (33) are provided on the radial guide rod (31). The first winding assembly (32) includes a first mounting base (321) and a winding mold base (322) provided on the first mounting base (321). The second winding assembly (33) includes a second mounting base (331) and a winding support shaft (332) provided on the second mounting base (331). At least one lateral clamping assembly (5) for preventing the coil from falling off is provided between the first winding assembly (32) and the second winding assembly (33). The first winding assembly (32) and / or the second winding assembly (33) are provided with a demolding mechanism (6) for the flat copper wire to be removed from the winding mold assembly (3) after winding.

2. The flat copper wire winding forming device according to claim 1, characterized in that: The demolding mechanism (6) includes a demolding slide (61) and a demolding drive (62). The demolding slide (61) and the demolding drive (62) are disposed on the second mounting base (331). The winding support shaft (332) is installed in the demolding slide (61). The demolding drive (62) is connected to the winding support shaft (332) and is used to drive the winding support shaft (332) to move closer to or away from the first winding assembly (32) along the demolding slide (61).

3. The flat copper wire winding forming device according to claim 2, characterized in that: The demolding drive component (62) includes a stepper motor (621) and a lead screw (622). The stepper motor (621) is mounted on the second mounting base (331). The lead screw (622) is connected to the output shaft of the stepper motor (621). The nut of the lead screw (622) is connected to the winding support shaft (332). The stepper motor (621) drives the lead screw (622) to rotate, causing the nut to drive the winding support shaft (332) to translate along the demolding groove (61).

4. The flat copper wire winding forming device according to claim 3, characterized in that: An insulating pad is fitted on the outer surface of the winding support shaft (332), and the insulating pad is any one of nylon sleeve, Teflon sleeve, polyoxymethylene sleeve, or polyetheretherketone sleeve.

5. The flat copper wire winding forming device according to claim 1, characterized in that: The first mounting base (321) and the second mounting base (331) are slidably mounted on the radial guide rod (31) via a linear drive mechanism (4).

6. The flat copper wire winding forming device according to claim 5, characterized in that: The linear drive mechanism (4) includes a geared motor (41) mounted on the first mounting base (321) or the second mounting base (331), a gear mounted on the output shaft of the geared motor (41), and a sliding guide rail (42) fixed on the radial guide rod (31). The sliding guide rail (42) is provided with a rack (421) that meshes with the gear. The geared motor (41) drives the gear to mesh with the rack (421), so that the first mounting base (321) or the second mounting base (331) moves axially along the radial guide rod (31).

7. The flat copper wire winding forming device according to claim 1, characterized in that: The lateral clamping assembly (5) includes a fixed support block (51), a clamping plate (52), and a clamping drive. The fixed support block (51) is mounted on the radial guide rod (31), and the clamping drive is mounted inside the fixed support block (51). The fixed support block (51) has a telescopic hole (54). The push rod of the clamping drive passes through the telescopic hole (54) and connects to the clamping plate (52) to drive the clamping plate (52) to reciprocate through the telescopic hole (54) in the axial direction to clamp or release the flat copper wire.

8. The flat copper wire winding forming device according to claim 7, characterized in that: The clamping plate (52) and the fixed support block (51) are provided with an elastic buffer layer to prevent damage to the insulation layer on the surface of the flat copper wire during clamping.

9. A flat copper wire winding forming process, implemented using the apparatus described in any one of claims 1 to 8, characterized in that, Includes the following steps: Step S1: According to the preset coil width, drive the first winding assembly (32) and the second winding assembly (33) to move relative to each other along the radial guide rod (31), and adjust the distance between the winding mold seat (322) and the winding support shaft (332) to the preset width; Step S2: Place the starting end of the flat copper wire between the clamping plate (52) and the fixed support block (51) of the lateral clamping assembly (5), and drive the clamping plate (52) to approach the fixed support block (51) through the clamping drive component to clamp the flat copper wire. Step S3: Start the rotating main disk (2) to wind the flat copper wire into a closed waist-shaped coil, and stop after winding to the preset number of turns; Step S4: Drive the clamping plate (52) away from the fixed support block (51) by the clamping drive component to release the flat copper wire; Step S5: Start the demolding drive (62) to drive the winding support shaft (332) to translate along the demolding slide (61) toward the first winding assembly (32) so that the coil is disengaged from the winding support shaft (332); Step S6: Remove the finished coil.

10. A flat copper wire winding forming process according to claim 9, characterized in that: In step S5, the translation process of the winding support shaft (332) includes: Step S51: Drive the winding support shaft (332) to translate by 0.1-0.5mm to break the static friction lock between the coil and the winding support shaft (332). At this time, the coil and the winding support shaft (332) are still not completely separated. Step S52: After the coil is released from its locked state, continue to drive the winding support shaft (332) to translate to the preset displacement, so that the coil is completely separated from the winding support shaft (332).

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