Axial flux motor PCB coil plate winding equipment and forming processing method

Abstract

The application relates to the field of axial flux motor coil processing technology and discloses an axial flux motor PCB coil plate winding equipment and a forming processing method, which comprises a base, the top of the base is fixedly connected with a closed rack, the middle of the base is fixedly connected with a bearing workbench used for placing a PCB coil plate, the outer edge of the bearing workbench is provided with a plurality of positioning modules, the plurality of positioning modules are distributed at equal angles around the bearing workbench, the inner side of the closed rack is provided with a gantry fixedly connected with the base, one end of the inner side of the gantry is provided with a wire supply module used for placing wire, one end of the gantry is movably provided with a winding module used for winding the wire on the PCB coil plate, and the other end of the gantry is provided with a constant-temperature pressing module. Through cooperation of the various modules, the technical defects of the prior art, such as the rigidity of the base plate clamping, the easy vibration of the plate, the unadjustable wire supply tension, the high wire breaking rate, the insufficient freedom of the winding needle, the perpendicularity and the roundness, are solved.

Description

Technical Field

[0001] This invention relates to the field of axial flux motor coil processing technology, specifically to an axial flux motor PCB coil winding equipment and forming processing method. Background Technology

[0002] Axial flux motors, due to their short axial dimension, high torque density, and excellent efficiency, have become an ideal drive solution for space-constrained applications such as drive motors for new energy vehicles, eVTOL aviation electric drives, and robot joint motors. Among them, the coreless PCB winding axial flux motor abandons the traditional silicon steel sheet stator core, with the windings directly fixed on a non-magnetic insulating substrate, eliminating stator iron loss and cogging effect at the source. Moreover, the coil shape, size, and positioning are extremely precise, and mass production can be achieved through PCB technology, resulting in good product consistency. It is one of the fastest technology routes for industrialization. Currently, the manufacturing of PCB coils for axial flux motors mainly relies on three types of solutions, but all of these solutions have certain technical drawbacks: 1. Traditional equipment often uses rigid pressure plates to press down on the PCB board from a single point on top, without distributed pressing around. When the winding needle moves back and forth at high speed, the edge of the substrate is prone to micron-level vibration and warping, resulting in deviation of turn spacing and a decrease in coil fill factor. 2. Traditional winding equipment often uses mechanical friction tensioners or fixed magnetic powder brakes for wire supply. The tension cannot be dynamically adjusted according to the wire diameter, and the response time is >10ms, which cannot adapt to the transient changes of starting, stopping, accelerating and decelerating during winding. Excessive tension can easily pull the copper wire thin and crack the insulating varnish film, causing short circuits between turns. Insufficient tension will result in loose coils, large interlayer gaps, and a decrease in the fill factor. 3. Traditional winding machines are mostly single-degree-of-freedom (rotation only) or three-degree-of-freedom (X-axis movement + lifting + rotation), which cannot adjust the circumferential angle of the winding needle in real time during the winding process. This results in the winding needle not being perpendicular to the PCB board surface at all times, inconsistent embedding depth of the enameled wire into the wire groove, and large roundness error of the planar helical trajectory. In view of this, the present invention proposes a winding equipment and forming method for axial flux motor PCB coil board. Summary of the Invention

[0003] This invention proposes a winding equipment and forming method for axial flux motor PCB coil boards, which solves the problems of rigid substrate clamping that easily damages the board and causes vibration, and the high breakage rate due to non-adjustable wire tension in the prior art.

[0004] The technical solution of the present invention is as follows: an axial flux motor PCB coil board winding device includes a base, a closed frame fixedly connected to the top of the base, a support worktable for placing the PCB coil board fixedly connected to the middle of the base, a plurality of positioning modules for pressing and fixing the PCB coil board are provided on the outer edge of the support worktable, the plurality of positioning modules are distributed at equal angles around the support worktable, a gantry frame fixedly connected to the base is provided on the inner side of the closed frame, a wire supply module for releasing wire is provided at one end of the inner side of the gantry frame, a winding module for winding wire onto the PCB coil board is movably provided at one end of the gantry frame, and a constant temperature pressing module for pressing and forming the PCB coil board is provided at the other end of the gantry frame.

[0005] Preferably, the positioning module includes a first cylinder fixedly connected to the top of the base, an output end of the first cylinder fixedly connected to an installation plate, a second cylinder fixedly connected to the top of the installation plate and perpendicular to the first cylinder, an output end of the second cylinder fixedly connected to a connecting plate, an elastic element provided at one end of the connecting plate, and a pressure block fixedly connected to the bottom of the elastic element.

[0006] Preferably, the elastic element includes a pressure rod that passes through the connecting plate and is slidably connected to the connecting plate. The bottom end of the pressure rod is fixedly connected to the pressure block, and a stop block is fixedly connected to the top of the pressure rod. A buffer spring is sleeved on the pressure rod, and the two ends of the buffer spring abut against the connecting plate and the pressure block, respectively.

[0007] Preferably, the wire supply module includes a winding roller rotatably connected to the inner side of the gantry and used for winding the wire; a first motor is fixedly connected to the outer side of the gantry, the output shaft of the first motor is fixedly connected to the winding roller; a slide rail is fixedly connected to the top of the inner side of the gantry, a movable seat is slidably connected to the slide rail, a tensioning roller is rotatably connected to the inner side of the movable seat, and an adjusting member is provided on the top of the gantry for driving the movable seat to slide.

[0008] Preferably, the adjusting component includes a lead screw rotatably connected to the inner side of the gantry frame, the lead screw being threadedly connected to the movable seat, and a second motor being fixedly installed on the outer side of the gantry frame, the output shaft of the second motor being fixedly connected to the lead screw.

[0009] Preferably, the winding module includes a first slider slidably connected to the top of the gantry frame, a mounting bracket fixedly connected to the top of the first slider, a third motor fixedly mounted on one side of the mounting bracket, a turntable fixedly connected to the output shaft of the third motor, a third cylinder fixedly connected to the outer side of the turntable, a fourth motor fixedly connected to the output end of the third cylinder, and a winding needle fixedly connected to the output shaft of the fourth motor.

[0010] Preferably, the top of the gantry frame is provided with a sliding groove that slides with the first slider, and the top of the gantry frame is fixedly connected with a guide tooth plate that is parallel to the sliding groove. A fifth motor is fixedly installed on the other side of the mounting frame, and the output shaft of the fifth motor is fixedly connected with a first traveling gear that meshes with the guide tooth plate.

[0011] Preferably, the constant temperature pressing module includes a second slider that slides in cooperation with the slide groove. A second mounting bracket is fixedly connected to the top of the second slider. A fourth cylinder is fixedly connected to one side of the second mounting bracket. A fifth cylinder is fixedly connected to the output end of the fourth cylinder. A constant temperature pressure plate is fixedly connected to the output end of the fifth cylinder. A sixth motor is fixedly installed on the other side of the second mounting bracket. A second traveling gear that meshes with a guide tooth plate is fixedly connected to the output shaft of the sixth motor.

[0012] Preferably, the thermostatic pressure plate is embedded with a heating wire, and a controller that is electrically connected to the heating wire is fixedly connected to the outside of the gantry frame.

[0013] This invention also provides a method for forming and processing an axial flux motor PCB coil board, which is implemented using an axial flux motor PCB coil board winding device and includes the following steps: S1. Loading and Positioning: The PCB coil board to be processed is placed in the center of the support worktable. Several positioning modules distributed around it are activated simultaneously: the first cylinder drives the mounting plate to rise vertically, which in turn drives the second cylinder and the connecting plate to rise to the preset working height; the second cylinder drives the connecting plate to feed horizontally towards the center of the support worktable, so that the pressure block moves directly above the PCB coil board; the second cylinder continues to move downward. After the pressure block contacts the surface of the PCB coil board, the pressure rod slides upward in the connecting plate and compresses the buffer spring. The rebound force of the buffer spring applies a uniform and flexible clamping force to the PCB coil board through the pressure block. The stop block limits the sliding limit of the pressure rod to prevent the pressure block from detaching, thus completing the circumferential multi-point fixation of the PCB board. S2. Wire tension adjustment: The first motor drives the winding roller to rotate at a constant speed to release the enameled wire. After the enameled wire passes over the tension roller, it is led to the winding needle. The second motor drives the lead screw to rotate, and through the screw drive, it drives the movable seat to slide along the slide rail to adjust the lateral position of the tension roller, change the envelope angle of the enameled wire, so that the tension roller applies a constant tension to the enameled wire that is suitable for the current wire diameter, and avoids the wire from being too loose or too tight. S3, Precision Winding: The winding module operates according to the preset coil arrangement trajectory. The fifth motor drives the first traveling gear to mesh with the guide tooth plate, which in turn drives the first slider to move along the slide groove in a large X-direction stroke. The third motor drives the turntable to rotate, adjusting the circumferential angle of the winding needle to ensure that the winding needle is always perpendicular to the PCB board surface. The third cylinder drives the fourth motor and the winding needle to move up and down in the vertical direction to adapt to the requirements of different wire diameters for cable stacking. The fourth motor drives the winding needle to rotate at high speed, controlling the output direction and rotation angle of the enameled wire; it precisely embeds the enameled wire into the designated slot on the PCB board to complete the winding of a planar spiral or multi-layered winding trajectory. The entire process is carried out in a closed frame, isolating external dust interference. S4. Constant Temperature Pressing and Forming: After winding is completed, the sixth motor drives the second traveling gear to mesh with the guide tooth plate, driving the second slider to slide along the slide groove and move the constant temperature pressure plate to the top of the PCB coil board; the fourth cylinder drives the fifth cylinder and the constant temperature pressure plate to move vertically downward as a whole, completing the coarse positioning of the pressure plate height; the fifth cylinder outputs precision pressure to push the constant temperature pressure plate to press onto the surface of the wound coil; the controller adjusts the current of the heating wire in the constant temperature pressure plate to keep the pressure plate at a constant process temperature, heating softens and bonds the insulating varnish on the surface of the enameled wire, realizing the curing and forming of the coil layer. After holding the pressure for the set time, the fifth cylinder and the fourth cylinder reset in sequence, and the constant temperature pressure plate is lifted. S5, Unloading: The second cylinder of the positioning module moves upward, causing the pressure block to detach from the PCB board surface. The first cylinder resets, causing the entire positioning module to fall back to the initial position. The formed PCB coil board is then removed, completing a single batch processing cycle.

[0014] The beneficial effects of this invention are as follows: 1. By setting several positioning modules at equal angles along the outer edge of the bearing worktable, the first cylinder drives the mounting plate to rise vertically, and the second cylinder drives the connecting plate to feed horizontally and move downward, so that the pressure block approaches the PCB coil board synchronously from multiple circumferential directions; the elastic element composed of the pressure rod and the buffer spring compresses and absorbs energy after the pressure block contacts the board surface, converting the rigid downward movement of the second cylinder into a uniform flexible clamping force transmitted through the rebound force of the buffer spring, and the stop block limits the sliding limit of the pressure rod to prevent the pressure block from detaching; this design completely solves the pain points of traditional top single-point rigid pressing, such as "micron-level vibration and warping of the substrate edge, turn pitch deviation, and decrease in filling coefficient", and multi-point pressure around the PCB board keeps it absolutely flat when the winding needle moves back and forth at high speed; the flexible buffer not only avoids damage to the brittle PCB substrate caused by rigid pressing, but also automatically compensates for the flatness error of the board surface, so that the multi-point clamping force is uniform and consistent, and adapts to the processing needs of boards of different thicknesses.

[0015] 2. The wire supply module uses a first motor to drive the winding roller at a constant speed for unwinding, and a second motor to drive the lead screw, which in turn drives the movable seat to slide along the slide rail via a threaded transmission. This adjusts the lateral position of the tension roller to change the envelope angle of the enameled wire, allowing the tension roller to apply a constant tension to the enameled wire that is suitable for the current wire diameter. This design overcomes the limitations of traditional mechanical friction tensioners or fixed magnetic powder brakes, which suffer from "tension not being dynamically adjustable according to wire diameter and having a sluggish response." It can optimize the tension force in real time according to the wire diameter: excessive tension can easily pull the copper wire thin and tear the insulating varnish film, causing inter-turn short circuits; insufficient tension will result in loose coils, large interlayer gaps, and a decrease in the fill factor. This solution achieves dynamic stability of the wire tension throughout the winding process through the combination of active unwinding and adjustable tension rollers, avoiding wire looseness or excessive tightness, fundamentally reducing the breakage rate and the risk of inter-turn short circuits, and improving the consistency of winding quality.

[0016] 3. The winding module integrates a fifth motor driving the first traveling gear to mesh with the guide tooth plate to achieve large-stroke X-axis movement, a third motor driving the turntable to rotate and adjust the circumferential angle of the winding needle, a third cylinder driving the fourth motor and the winding needle to lift and lower in the Z-axis, and a fourth motor driving the winding needle to rotate at high speed, constructing a multi-degree-of-freedom composite motion system of "X-axis movement + circumferential rotation + rotation + Z-axis lifting and lowering". This design precisely addresses the shortcomings of traditional winding machines that "single-degree-of-freedom or three-degree-of-freedom cannot adjust the circumferential angle of the winding needle in real time during the winding process". The turntable's rotation adjustment capability ensures that the winding needle is always perpendicular to the PCB board surface, ensuring consistent depth of the enameled wire embedded in the wire groove and significantly reducing the roundness error of the planar helical trajectory. The gear and rack transmission provides high-response displacement control, meeting the dynamic performance requirements of precision wiring, and can accurately reproduce the winding trajectory of complex axial flux motor coils such as planar helices and multi-layer lap windings, significantly improving coil filling density and electrical performance.

[0017] 4. The second slider of the constant temperature pressing module shares the same slide groove and guide tooth plate as the first slider of the winding module. The sixth motor drives the second traveling gear to achieve X-axis station switching. The fourth cylinder is responsible for coarse positioning of the pressing plate height, and the fifth cylinder outputs precision pressure to achieve micron-level fine pressing. The controller adjusts the current of the heating wire in the constant temperature pressing plate to keep the pressing plate at a constant process temperature. This design achieves seamless connection between the winding and pressing processes in the same station, avoiding repeated positioning errors in the process flow. The four-stage cylinder's "coarse positioning + fine pressing" two-stage pressure control ensures sufficient mold clamping force and achieves precise control of the pressing force. Constant temperature heating activates the adhesive properties of the insulating varnish on the surface of the enameled wire, making the coil layers firmly bonded together, significantly enhancing the overall mechanical strength and heat resistance of the coil, and preventing the coil from loosening or shifting due to centrifugal force or thermal stress during motor operation. Attached Figure Description

[0018] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0019] Figure 1 This is a schematic diagram of the structure of an axial flux motor PCB coil winding device according to the present invention. Figure 1 ; Figure 2 This is a schematic diagram of the structure of an axial flux motor PCB coil winding device according to the present invention. Figure 2 ; Figure 3 This is a schematic diagram of the positioning module of the present invention; Figure 4 This is a schematic diagram of the gantry structure of the present invention; Figure 5 This is a schematic diagram of the wire supply module of the present invention; Figure 6 This is a schematic diagram of the structure of the adjusting component of the present invention; Figure 7 This is a schematic diagram of the winding module of the present invention; Figure 8 This is a schematic diagram of the isothermal pressing module of the present invention.

[0020] In the diagram: 1. Base; 2. Enclosed frame; 3. Supporting worktable; 4. PCB coil board; 5. Positioning module; 51. First cylinder; 52. Mounting plate; 53. Second cylinder; 54. Connecting plate; 55. Pressure rod; 56. Pressure block; 57. Stop block; 58. Buffer spring; 6. Gantry frame; 61. Slide groove; 62. Guide tooth plate; 7. Wire supply module; 71. Winding roller; 72. First motor; 73. Slide rail; 74. Movable seat; 75. Tensioning roller; 76. Adjusting component 761. Lead screw; 762. Second motor; 8. Winding module; 81. First slider; 82. Mounting bracket; 83. Third motor; 84. Turntable; 85. Third cylinder; 86. Fourth motor; 87. Winding needle; 88. Fifth motor; 89. First traveling gear; 9. Thermostatic pressing module; 91. Second slider; 92. Second mounting bracket; 93. Fourth cylinder; 94. Fifth cylinder; 95. Thermostatic pressing plate; 96. Sixth motor; 97. Second traveling gear. Detailed Implementation

[0021] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0022] like Figures 1 to 8As shown, this embodiment proposes an axial flux motor PCB coil board winding device, including a base 1, a closed frame 2 fixedly connected to the top of the base 1, a support worktable 3 for placing the PCB coil board 4 fixedly connected to the middle of the base 1, a plurality of positioning modules 5 for pressing and fixing the PCB coil board 4 are provided on the outer edge of the support worktable 3, the plurality of positioning modules 5 are distributed at equal angles around the support worktable 3, a gantry 6 fixedly connected to the base 1 is provided on the inner side of the closed frame 2, a wire supply module 7 for releasing wire is provided on one end of the inner side of the gantry 6, a winding module 8 for winding wire on the PCB coil board 4 is movably provided on one end of the gantry 6, and a constant temperature pressing module 9 for pressing and forming the PCB coil board 4 is provided on the other end of the gantry 6.

[0023] In this embodiment, after the equipment is started, several positioning modules 5 operate synchronously, pressing and fixing the PCB coil board 4 onto the support worktable 3 from multiple circumferential directions. The wire supply module 7 begins to release the wire and maintains a constant tension on the wire during the conveying process; the winding module 8, according to the preset coil arrangement trajectory, drives the winding needle 87 to precisely wind the wire into the designated slot of the PCB coil board 4 through multi-dimensional linkage of moving in the X-axis direction, rotating around the vertical axis, and rotating on its own axis. After winding is completed, the constant temperature pressing module 9 moves to directly above the PCB coil board 4, applying constant pressure while heating and keeping the coil warm, so that the insulating varnish on the surface of the enameled wire softens and adheres, realizing the curing and forming of the coil layer. The entire operation is completed within the enclosed frame 2, avoiding external dust interference. The positioning module 5, with its equidistant surrounding design, provides multi-point uniform clamping force, effectively suppressing minor vibrations and warping deformation of the PCB coil board 4 during high-speed winding, ensuring consistent coil turn spacing. The introduction of an elastic buffer structure avoids damage to the brittle PCB substrate caused by rigid clamping, adapting to the processing requirements of boards of different thicknesses. The dynamic tension adjustment function of the wire supply module 7 solves the problem of uneven wire alignment caused by slack or pulling, ensuring consistent wire tension. The multi-degree-of-freedom linkage control of the winding module 8 achieves high-precision reproduction of complex trajectories such as planar spirals and multi-layered windings, significantly improving… The constant temperature pressing module 9 integrates pressurization and heating functions, completing the hot pressing and shaping of the coil at the same station. This activates the bonding characteristics of the enameled wire insulation varnish, enhances the overall mechanical strength and heat resistance of the coil, and prevents the finished coil from loosening or shifting during subsequent motor operation. All functional modules are integrated on the gantry 6 inside the enclosed frame 2, resulting in a compact structure and smooth process connection, reducing repetitive positioning errors caused by process flow. The enclosed working environment effectively isolates external dust, hair, and other foreign objects from interfering with the precision coil winding process, improving the product yield and cleanliness.

[0024] In a further preferred embodiment of the present invention, the positioning module 5 includes a first cylinder 51 fixedly connected to the top of the base 1. The output end of the first cylinder 51 is fixedly connected to a mounting plate 52. The top of the mounting plate 52 is fixedly connected to a second cylinder 53 that is perpendicular to the first cylinder 51. The output end of the second cylinder 53 is fixedly connected to a connecting plate 54. One end of the connecting plate 54 is provided with an elastic element. The bottom of the elastic element is fixedly connected to a pressure block 56. The elastic element includes a pressure rod 55 that passes through the connecting plate 54 and is slidably connected to the connecting plate 54. The bottom end of the pressure rod 55 is fixedly connected to the pressure block 56. The top of the pressure rod 55 is fixedly connected to a stop block 57. A buffer spring 58 is sleeved on the pressure rod 55. The two ends of the buffer spring 58 abut against the connecting plate 54 and the pressure block 56, respectively.

[0025] In this embodiment, after the first cylinder 51 is activated, it drives the mounting plate 52 to rise vertically, which in turn drives the second cylinder 53 and the connecting plate 54 to rise to the preset working height. The second cylinder 53 then drives the connecting plate 54 to move horizontally towards the center of the support worktable 3, so that the pressure block 56 moves directly above the PCB coil board 4. The second cylinder 53 continues to move downward. After the pressure block 56 contacts the surface of the PCB coil board 4, the pressure rod 55 slides upward in the connecting plate 54, compressing the buffer spring 58. The rebound force of the buffer spring 58 continues to act on the PCB coil board 4 through the pressure block 56 to achieve flexible pressing. The stop block 57 limits the upward sliding limit of the pressure rod 55 to prevent the pressure block 56 from detaching. The right-angle layout of the secondary cylinder in this design enables the pressure block 56 to move from avoidance to clamping in a complex motion trajectory, adapting to PCB coil boards 4 with different outer diameters; the elastic buffering effect of the buffer spring 58 avoids brittle fracture or micro-cracks of the PCB board caused by rigid clamping, while compensating for the flatness error of the PCB board surface and ensuring uniform clamping force at multiple points; multiple positioning modules 5 distributed in a ring apply pressure synchronously from multiple directions around the circumference, effectively suppressing the warping deformation of the PCB coil board 4 during the winding process and ensuring the accuracy of the coil turn arrangement.

[0026] In a further preferred embodiment of the present invention, the wire supply module 7 includes a winding roller 71 rotatably connected to the inner side of the gantry 6 for winding the wire. A first motor 72 is fixedly connected to the outer side of the gantry 6, and the output shaft of the first motor 72 is fixedly connected to the winding roller 71. A slide rail 73 is fixedly connected to the top of the inner side of the gantry 6, and a movable seat 74 is slidably connected to the slide rail 73. A tension roller 75 is rotatably connected to the inner side of the movable seat 74. An adjusting member 76 for driving the movable seat 74 to slide is provided on the top of the gantry 6. The adjusting member 76 includes a lead screw 761 rotatably connected to the inner side of the gantry 6 and threadedly connected to the movable seat 74. A second motor 762 is fixedly installed on the outer side of the gantry 6, and the output shaft of the second motor 762 is fixedly connected to the lead screw 761.

[0027] In this embodiment, the first motor 72 drives the winding roller 71 to rotate at a constant speed, releasing the enameled wire to the tension roller 75; the second motor 762 drives the lead screw 761 to rotate, which drives the movable seat 74 to slide along the slide rail 73 through the threaded transmission, adjusting the lateral position of the tension roller 75 at the top of the gantry 6, changing the envelope angle and stroke length of the enameled wire; when the enameled wire passes over the tension roller 75, the tension roller 75 rotates freely with the wire, maintaining the constant tension output of the wire by its own gravity or preset tension; This design achieves dynamic stability of wire tension during winding through the combination of active unwinding and adjustable tension roller 75, avoiding coil loosening, wire stacking, or wire breakage caused by tension fluctuations. The precision adjustment capability of lead screw 761 allows for real-time optimization of tension force according to wire diameter, adapting to the processing requirements of different wire specifications. The guiding constraint of slide rail 73 ensures the straightness of tension roller 75 adjustment process, preventing wire deviation or wear and improving the consistency of winding quality.

[0028] In a further preferred embodiment of the present invention, the winding module 8 includes a first slider 81 slidably connected to the top of the gantry frame 6. A mounting bracket 82 is fixedly connected to the top of the first slider 81. A third motor 83 is fixedly mounted on one side of the mounting bracket 82. A turntable 84 is fixedly connected to the output shaft of the third motor 83. A third cylinder 85 is fixedly connected to the outer side of the turntable 84. A fourth motor 86 is fixedly connected to the output end of the third cylinder 85. A winding needle 87 is fixedly connected to the output shaft of the fourth motor 86. A groove 61 is provided on the top of the gantry frame 6 to slide and engage with the first slider 81. A guide tooth plate 62 is fixedly connected to the top of the gantry frame 6 and is parallel to the groove 61. A fifth motor 88 is fixedly mounted on the other side of the mounting bracket 82. A first traveling gear 89 that meshes with the guide tooth plate 62 is fixedly connected to the output shaft of the fifth motor 88.

[0029] In this embodiment, the fifth motor 88 drives the first traveling gear 89 to rotate, and through meshing with the guide tooth plate 62, drives the first slider 81 to slide along the slide groove 61, realizing the large X-axis stroke movement of the winding needle 87; the third motor 83 drives the turntable 84 to rotate, causing the winding needle 87 to swing circumferentially around the vertical axis to adjust the winding angle; the fourth motor 86 directly drives the winding needle 87 to rotate at high speed, controlling the wire exit direction and rotation angle; the third cylinder 85 drives the fourth motor 86 and the winding needle 87 to rise and fall in the vertical direction, realizing the stacking of wires of different diameters; the parallel arrangement of the slide groove 61 and the guide tooth plate 62 ensures the stability of the walking process; This module achieves composite motion of the winding needle 87 in five degrees of freedom—X-axis movement, circumferential rotation, self-rotation, and Z-axis lifting—through multi-motor coordinated drive. It can accurately reproduce complex axial flux motor coil winding trajectories such as planar helical and multi-layered winding. The gear and rack transmission method provides high-response displacement control, meeting the dynamic performance requirements of precision wiring. The rotation adjustment capability of the turntable 84 ensures that the winding needle 87 is always perpendicular to the PCB board surface, ensuring consistent wire embedding depth in the wire slot and improving the coil fill factor and electrical performance.

[0030] In a further preferred embodiment of the present invention, the constant temperature pressing module 9 includes a second slider 91 that slides in cooperation with the slide groove 61. A second mounting bracket 92 is fixedly connected to the top of the second slider 91. A fourth cylinder 93 is fixedly connected to one side of the second mounting bracket 92. A fifth cylinder 94 is fixedly connected to the output end of the fourth cylinder 93. A constant temperature pressure plate 95 is fixedly connected to the output end of the fifth cylinder 94. A sixth motor 96 is fixedly installed on the other side of the second mounting bracket 92. A second traveling gear 97 that meshes with the guide tooth plate 62 is fixedly connected to the output shaft of the sixth motor 96. A heating wire is embedded in the constant temperature pressure plate 95. A controller that is electrically connected to the heating wire is fixedly connected to the outside of the gantry 6.

[0031] In this embodiment, the sixth motor 96 drives the second traveling gear 97 to rotate, and through meshing with the guide tooth plate 62, drives the second slider 91 to slide along the slide groove 61, moving the thermostatic pressure plate 95 to directly above the PCB coil board 4; the fourth cylinder 93 drives the fifth cylinder 94 and the thermostatic pressure plate 95 to move vertically downwards to near the surface of the PCB board; the fifth cylinder 94 then outputs precision pressure to push the thermostatic pressure plate 95 to press against the surface of the wound coil; the controller adjusts the current of the heating wire inside the thermostatic pressure plate 95 to keep the pressure plate at a constant process temperature, and performs hot pressing shaping on the coil; This module simplifies the equipment structure by sharing the slide groove 61 and guide tooth plate 62 with the winding module 8, and achieves seamless connection between the winding and pressing processes at the same station, avoiding positioning errors in the process flow; the fourth cylinder 93 is responsible for coarse positioning and the fifth cylinder 94 is responsible for the two-stage pressure control of fine pressing, which not only ensures sufficient clamping force, but also achieves micron-level precise control of the pressing force; the constant temperature heating function activates the adhesive properties of the insulating varnish on the surface of the enameled wire, so that the coil layers are firmly bonded together, significantly enhancing the overall mechanical strength and heat resistance of the coil, and preventing the coil from loosening due to centrifugal force or thermal stress during motor operation.

[0032] Overall workflow: 1. Loading and Positioning Stage: The PCB coil board to be processed is placed in the center of the support worktable. Several surrounding positioning modules are activated simultaneously: the first cylinder drives the mounting plate to rise vertically, which in turn drives the second cylinder and the connecting plate to rise to the preset working height; the second cylinder drives the connecting plate to feed horizontally towards the center of the support worktable, so that the pressure block moves directly above the PCB coil board; the second cylinder continues to move downward. After the pressure block contacts the surface of the PCB board, the pressure rod slides upward in the connecting plate and compresses the buffer spring. The rebound force of the buffer spring applies a uniform and flexible clamping force to the PCB board through the pressure block. The stop block limits the sliding limit of the pressure rod to prevent the pressure block from detaching, thus completing the circumferential multi-point fixation of the PCB board. II. Wire Tension Adjustment Stage: The wire supply module starts synchronously. The first motor drives the winding roller to rotate at a constant speed to release the enameled wire. After the enameled wire passes over the tension roller, it is led to the winding needle. The second motor drives the lead screw to rotate, which drives the movable seat to slide along the slide rail through the screw drive. This adjusts the lateral position of the tension roller, changes the envelope angle of the enameled wire, and makes the tension roller apply a constant tension to the enameled wire that is suitable for the current wire diameter, so as to avoid the wire being too loose or too tight.

[0033] III. Precision Winding Stage: The winding module operates according to the preset coil arrangement trajectory: The fifth motor drives the first traveling gear to mesh with the guide tooth plate, driving the first slider to move along the slide groove in a large X-axis stroke; the third motor drives the turntable to rotate, adjusting the circumferential angle of the winding needle to ensure that the winding needle is always perpendicular to the PCB board surface; the third cylinder drives the fourth motor and the winding needle to rise and fall in the vertical direction to adapt to the requirements of different wire diameters for wire stacking; the fourth motor drives the winding needle to rotate at high speed, controlling the wire exit direction and rotation angle of the enameled wire, accurately embedding the enameled wire into the designated wire groove of the PCB board, completing the winding of a planar spiral or multi-layer stacked trajectory. The entire process is carried out in a closed frame, isolating external dust interference. IV. Thermostatic Pressing Forming Stage: After winding is completed, the thermostatic pressing module is activated: the sixth motor drives the second traveling gear to mesh with the guide tooth plate, driving the second slider to slide along the slide groove, moving the thermostatic pressing plate directly above the PCB coil board; the fourth cylinder drives the fifth cylinder and the thermostatic pressing plate to move vertically downwards, completing the coarse positioning of the pressing plate height; the fifth cylinder outputs precision pressure, pushing the thermostatic pressing plate to press onto the surface of the wound coil; the controller adjusts the current of the heating wire in the thermostatic pressing plate to keep the pressing plate at a constant process temperature, heating softens and bonds the insulating varnish on the surface of the enameled wire, realizing the curing and forming of the coil layer; after holding the pressure for the set time, the fifth cylinder and the fourth cylinder reset in sequence, and the thermostatic pressing plate is lifted; V. Unloading stage: The second cylinder of the positioning module moves upward to drive the pressure block away from the PCB board surface, the first cylinder resets and drives the positioning module back to the initial position, and the formed PCB coil board is taken out, completing a single batch processing cycle.

[0034] This invention also provides a method for forming and processing an axial flux motor PCB coil board, which is implemented using an axial flux motor PCB coil board winding device and includes the following steps: S1. Loading and Positioning: The PCB coil board 4 to be processed is placed at the center of the support worktable 3. Several surrounding positioning modules 5 are activated simultaneously: the first cylinder 51 drives the mounting plate 52 to rise vertically, driving the second cylinder 53 and the connecting plate 54 to the preset working height; the second cylinder 53 drives the connecting plate 54 to move horizontally towards the center of the support worktable 3, so that the pressure block 56 moves directly above the PCB coil board 4; the second cylinder 53 continues to move downward. After the pressure block 56 contacts the surface of the PCB coil board 4, the pressure rod 55 slides upward in the connecting plate 54 and compresses the buffer spring 58. The rebound force of the buffer spring 58 applies a uniform and flexible clamping force to the PCB coil board 4 through the pressure block 56. The stop block 57 limits the sliding limit of the pressure rod 55 to prevent the pressure block 56 from detaching, thus completing the circumferential multi-point fixing of the PCB board. S2. Wire tension adjustment: The first motor 72 drives the winding roller 71 to rotate at a constant speed to release the enameled wire. After the enameled wire passes over the tension roller 75, it is led to the winding needle 87. The second motor 762 drives the lead screw 761 to rotate, and through the screw drive, the movable seat 74 slides along the slide rail 73 to adjust the lateral position of the tension roller 75, change the envelope angle of the enameled wire, so that the tension roller 75 applies a constant tension to the enameled wire that is suitable for the current wire diameter, and avoids the wire from being too loose or too tight. S3, Precision Winding: The winding module 8 operates according to the preset coil arrangement trajectory. The fifth motor 88 drives the first traveling gear 89 to mesh with the guide tooth plate 62, thereby driving the first slider 81 to move along the slide groove 61 in a large X-direction stroke. The third motor 83 drives the turntable 84 to rotate, adjusting the circumferential angle of the winding needle 87 to ensure that the winding needle 87 is always perpendicular to the PCB board surface. The third cylinder 85 drives the fourth motor 86 and the winding needle 87 to move up and down in the vertical direction to adapt to the requirements of different wire diameters for cable stacking. The fourth motor 86 drives the winding needle 87 to rotate at high speed, controlling the output direction and rotation angle of the enameled wire; the enameled wire is precisely embedded into the designated wire slot of the PCB board to complete the winding of the planar spiral or multi-layer overlapping trajectory. The whole process is carried out in the closed frame 2, which isolates external dust interference. S4. Constant Temperature Pressing and Shaping: After the winding is completed, the sixth motor 96 drives the second traveling gear 97 to mesh with the guide tooth plate 62, driving the second slider 91 to slide along the slide groove 61, moving the constant temperature pressure plate 95 to directly above the PCB coil board 4; the fourth cylinder 93 drives the fifth cylinder 94 and the constant temperature pressure plate 95 to move vertically downward as a whole, completing the coarse positioning of the pressure plate height; the fifth cylinder 94 outputs precision pressure, pushing the constant temperature pressure plate 95 to press onto the surface of the wound coil; the controller adjusts the current of the heating wire inside the constant temperature pressure plate 95 to keep the pressure plate at a constant process temperature, heating softens and bonds the insulating varnish on the surface of the enameled wire, realizing the curing and shaping of the coil layer; after holding the pressure for the set time, the fifth cylinder 94 and the fourth cylinder 93 reset in sequence, and the constant temperature pressure plate 95 is lifted; S5, Unloading: The second cylinder 53 of the positioning module 5 moves upward to drive the pressure block 56 to detach from the PCB board surface, and the first cylinder 51 resets to drive the positioning module 5 back to the initial position. The formed PCB coil board 4 is then taken out, completing a single batch processing cycle.

[0035] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A winding device for an axial flux motor PCB coil board, characterized in that, include: Base (1); A closed frame (2) is fixedly connected to the top of the base (1); A support worktable (3) is fixedly connected to the middle of the base (1) and is used to place the PCB coil board (4). A plurality of positioning modules (5) are disposed on the outer edge of the bearing worktable (3) and used to press and fix the PCB coil board (4). The plurality of positioning modules (5) are distributed at equal angles around the bearing worktable (3). The gantry frame (6) is located inside the enclosed frame (2) and is fixedly connected to the base (1). A wire supply module (7) is installed at one end of the inner side of the gantry (6) and is used to release the wire. A winding module (8) is set at one end of the gantry (6) and is used to wind wires onto the PCB coil board (4). The active setting is a thermostatic pressing module (9) at the other end of the gantry (6) for pressing and molding the PCB coil board (4).

2. The axial flux motor PCB coil winding equipment according to claim 1, characterized in that, The positioning module (5) includes a first cylinder (51) fixedly connected to the top of the base (1). The output end of the first cylinder (51) is fixedly connected to a mounting plate (52). The top of the mounting plate (52) is fixedly connected to a second cylinder (53) that is perpendicular to the first cylinder (51). The output end of the second cylinder (53) is fixedly connected to a connecting plate (54). One end of the connecting plate (54) is provided with an elastic element. The bottom of the elastic element is fixedly connected to a pressure block (56).

3. The axial flux motor PCB coil winding equipment according to claim 2, characterized in that, The elastic element includes a pressure rod (55) that passes through the connecting plate (54) and is slidably connected to the connecting plate (54). The bottom end of the pressure rod (55) is fixedly connected to the pressure block (56), and a stop block (57) is fixedly connected to the top of the pressure rod (55). A buffer spring (58) is sleeved on the pressure rod (55), and the two ends of the buffer spring (58) abut against the connecting plate (54) and the pressure block (56) respectively.

4. The axial flux motor PCB coil winding equipment according to claim 3, characterized in that, The wire supply module (7) includes a winding roller (71) rotatably connected to the inner side of the gantry (6) for winding the wire. A first motor (72) is fixedly connected to the outer side of the gantry (6). The output shaft of the first motor (72) is fixedly connected to the winding roller (71). A slide rail (73) is fixedly connected to the top of the inner side of the gantry (6). A movable seat (74) is slidably connected to the slide rail (73). A tension roller (75) is rotatably connected to the inner side of the movable seat (74). An adjusting member (76) for driving the movable seat (74) to slide is provided on the top of the gantry (6).

5. The axial flux motor PCB coil winding equipment according to claim 4, characterized in that, The adjusting component (76) includes a lead screw (761) rotatably connected to the inner side of the gantry frame (6). The lead screw (761) is threadedly connected to the movable seat (74). A second motor (762) is fixedly installed on the outer side of the gantry frame (6). The output shaft of the second motor (762) is fixedly connected to the lead screw (761).

6. The axial flux motor PCB coil winding equipment according to claim 5, characterized in that, The winding module (8) includes a first slider (81) slidably connected to the top of the gantry (6). A mounting bracket (82) is fixedly connected to the top of the first slider (81). A third motor (83) is fixedly installed on one side of the mounting bracket (82). A turntable (84) is fixedly connected to the output shaft of the third motor (83). A third cylinder (85) is fixedly connected to the outside of the turntable (84). A fourth motor (86) is fixedly connected to the output end of the third cylinder (85). A winding needle (87) is fixedly connected to the output shaft of the fourth motor (86).

7. The axial flux motor PCB coil winding equipment according to claim 6, characterized in that, The top of the gantry (6) is provided with a slide groove (61) that slides with the first slider (81). The top of the gantry (6) is fixedly connected with a guide tooth plate (62) that is parallel to the slide groove (61). The other side of the mounting frame (82) is fixedly installed with a fifth motor (88). The output shaft of the fifth motor (88) is fixedly connected with a first traveling gear (89) that meshes with the guide tooth plate (62).

8. The axial flux motor PCB coil winding equipment according to claim 7, characterized in that, The constant temperature pressing module (9) includes a second slider (91) that slides in cooperation with the slide groove (61). A second mounting bracket (92) is fixedly connected to the top of the second slider (91). A fourth cylinder (93) is fixedly connected to one side of the second mounting bracket (92). A fifth cylinder (94) is fixedly connected to the output end of the fourth cylinder (93). A constant temperature pressure plate (95) is fixedly connected to the output end of the fifth cylinder (94). A sixth motor (96) is fixedly installed on the other side of the second mounting bracket (92). A second traveling gear (97) meshing with a guide tooth plate (62) is fixedly connected to the output shaft of the sixth motor (96).

9. The axial flux motor PCB coil winding equipment according to claim 8, characterized in that, The thermostatic pressure plate (95) is embedded with a heating wire, and the outer side of the gantry (6) is fixedly connected to a controller that is electrically connected to the heating wire.

10. A method for forming and processing an axial flux motor PCB coil board, implemented using the axial flux motor PCB coil board winding equipment according to claim 9, characterized in that, Includes the following steps: S1. Loading and positioning: Place the PCB coil board (4) to be processed in the center of the support worktable (3), and start the positioning modules (5) distributed around it simultaneously: the first cylinder (51) drives the mounting plate (52) to rise vertically, driving the second cylinder (53) and the connecting plate (54) to rise to the preset working height; the second cylinder (53) drives the connecting plate (54) to feed horizontally towards the center of the support worktable (3), so that the pressure block (56) moves to the top of the PCB coil board (4); The second cylinder (53) continues to move downward. After the pressure block (56) contacts the surface of the PCB coil board (4), the pressure rod (55) slides upward in the connecting plate (54) and compresses the buffer spring (58). The rebound force of the buffer spring (58) applies a uniform and flexible clamping force to the PCB coil board (4) through the pressure block (56). The stop block (57) limits the sliding limit of the pressure rod (55) to prevent the pressure block (56) from coming off, thus completing the circumferential multi-point fixation of the PCB board. S2, Wire tension adjustment: The first motor (72) drives the winding roller (71) to rotate at a constant speed to release the enameled wire. The enameled wire passes over the tension roller (75) and is then led to the winding needle (87). The second motor (762) drives the lead screw (761) to rotate. Through the screw drive, the movable seat (74) slides along the slide rail (73) to adjust the lateral position of the tension roller (75), change the envelope angle of the enameled wire, and make the tension roller (75) apply a constant tension to the enameled wire that is suitable for the current wire diameter, so as to avoid the wire from being too loose or too tight. S3, Precision winding: The winding module (8) operates according to the preset coil arrangement trajectory: The fifth motor (88) drives the first traveling gear (89) to mesh with the guide tooth plate (62) and drive the first slider (81) to move along the slide groove (61) in a large X-direction stroke. The third motor (83) drives the turntable (84) to rotate, and adjusts the circumferential angle of the winding needle (87) to ensure that the winding needle (87) is always perpendicular to the PCB board surface. The third cylinder (85) drives the fourth motor (86) and the winding needle (87) to rise and fall in the vertical direction to adapt to the requirements of different wire diameters of wire stacking; The fourth motor (86) drives the winding needle (87) to rotate at high speed, controlling the output direction and rotation angle of the enameled wire; the enameled wire is precisely embedded into the designated slot of the PCB board to complete the winding of the planar spiral or multi-layer overlapping trajectory. The whole process is carried out in the closed frame (2) to isolate external dust interference. S4. Constant Temperature Pressing and Molding: After the winding is completed, the sixth motor (96) drives the second traveling gear (97) to mesh with the guide tooth plate (62) and drive the second slider (91) to slide along the slide groove (61) to move the constant temperature pressure plate (95) to the top of the PCB coil board (4); the fourth cylinder (93) drives the fifth cylinder (94) and the constant temperature pressure plate (95) to move vertically downward as a whole to complete the rough positioning of the pressure plate height; the fifth cylinder (94) outputs precision pressure to push the constant temperature pressure plate (95) to press on the surface of the wound coil; the controller adjusts the current of the heating wire in the constant temperature pressure plate (95) to keep the pressure plate at a constant process temperature, and the heating softens and bonds the insulating varnish on the surface of the enameled wire to achieve the curing and molding of the coil layer. After the pressure is held for a set time, the fifth cylinder (94) and the fourth cylinder (93) are reset in sequence, and the constant temperature pressure plate (95) is lifted. S5, Unloading: The second cylinder (53) of the positioning module (5) moves upward to drive the pressure block (56) to detach from the PCB board surface. The first cylinder (51) resets and drives the positioning module (5) to fall back to the initial position. The formed PCB coil board (4) is taken out, and the single batch processing cycle is completed.

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