Horizontal inductive fully automatic forming system

Abstract

The present application relates to the technical field of inductance production and manufacturing, in particular to a horizontal inductance full-automatic forming system, comprising an automatic feeding module, a horizontal winding forming module, a terminal forming and connecting module, an appearance shaping and encapsulating module, an online detection module and a central control module; the automatic feeding module realizes wire constant tension conveying and magnetic core directional feeding, the horizontal winding forming module completes precise wire winding in the horizontal direction, the terminal forming and connecting module completes lead-out wire cutting and stripping and reliable terminal connection, the appearance shaping and encapsulating module completes size calibration, pin shaping and insulation encapsulation, the online detection module completes product performance and appearance detection, and the central control module realizes full-process centralized control and closed-loop quality control. The system realizes horizontal inductance full-process automatic continuous production, reduces quality deviation caused by human factors, improves product performance consistency and connection reliability, can realize full-quantity detection and quality traceability, and is suitable for quality control requirements of large-scale production.

Description

Technical Field

[0001] This invention relates to the field of inductor manufacturing technology, and in particular to a fully automated horizontal inductor forming system. Background Technology

[0002] Traditional horizontal inductor production often employs a semi-automated, manual operation model. Each production process is independent, requiring manual intervention and material handling at multiple stages, from core loading and winding to terminal connection and finished product inspection. Manual loading and unloading can easily result in core damage and wire scratches. The winding process requires operators to manually adjust tension and check the number of turns, leading to low production efficiency and variations in coil tightness and number of turns within the same batch due to individual operator differences, resulting in inconsistent inductance. In the terminal connection process, manual cutting, stripping, and crimping have significant operational errors, easily leading to incomplete insulation removal, damage to the wire core during stripping, and uneven crimping force. Ultimately, this results in insufficient reliability of the lead-to-terminal connection, unstable contact resistance, and negatively impacts the product's electrical performance.

[0003] Existing automated production equipment for horizontal inductors mostly covers only single processes such as winding. There is a lack of unified scheduling and control between the equipment in each process, and material handling still requires manual intervention, making it difficult to form a continuous, fully automated production process. Furthermore, the tension control of existing winding equipment often uses open-loop adjustment or a simple single-stage tension structure. During winding acceleration, deceleration, and layer switching, the wire tension fluctuates significantly, easily leading to problems such as wire breakage, excessive gaps between coil turns, and uneven winding tension, thus affecting the quality stability of the inductor. The performance testing in the existing production process mostly relies on manual offline sampling, covering only a small number of products with a high rate of missed inspections. Moreover, the quality data obtained cannot be directly fed back to previous production processes for adjusting process parameters, making it difficult to form a complete quality control closed loop. It is also impossible to retain production process data for each product, making it difficult to trace the source of quality problems and hindering continuous process optimization.

[0004] With the rapid development of downstream application fields such as new energy vehicles, industrial control, and communication equipment, the requirements for the electrical performance consistency, structural reliability, and insulation protection performance of horizontal inductors in related application scenarios are constantly increasing. The production capacity of traditional semi-manual production mode and existing single-process automated equipment can no longer meet the quality requirements of the downstream market, nor can it meet the quality control needs under large-scale production. There is an urgent need for fully automated production equipment adapted to horizontal inductors to solve the above problems. Summary of the Invention

[0005] The present invention proposes a fully automated horizontal inductor molding system to solve the problems mentioned in the prior art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a horizontal inductor fully automated molding system, comprising the following modules: The automatic feeding module is used to transport the winding wire from the pay-off reel to the winding station via a multi-stage tension adaptive adjustment device. At the same time, the magnetic core blanks are oriented and separated one by one by a vibratory feeder and then transported to the magnetic core assembly station via a linear feeding track. The horizontal winding forming module is located behind the automatic feeding module. It is used to precisely wind the wire into the magnetic core blank in the horizontal direction according to the preset number of turns, layers and winding pitch to form a coil winding. The module includes a horizontal spindle drive mechanism, a precision wire laying mechanism, a tension closed-loop feedback mechanism and a turn metering and interlayer switching control mechanism. The terminal forming and connection module is located behind the horizontal winding forming module. It is used to perform fixed-length cutting, insulation layer ring cutting and peeling, and crimping or resistance welding operations on the lead wire ends of the coil winding and the terminal to form a reliable electrical connection with low contact resistance between the lead wire ends and the terminal. The shape shaping and encapsulation module is located behind the terminal forming and connection module. It is used to perform shape and size calibration, pin bending and shaping, and to encapsulate the inductor semi-finished product with an insulating protective layer through injection molding or impregnation to form the final product shape. The online testing module, located behind the shape-forming and encapsulation module, is used to measure the inductance, DC resistance, inter-turn insulation withstand voltage test, and visually inspect the appearance defects of the formed inductor products. It also compares the test data with preset quality standard thresholds to determine whether the product is qualified. The central control module is connected to each of the above modules via an industrial fieldbus. It is used to centrally set the operating parameters of each module, monitor the operating status in real time, and record and store data. It also automatically adjusts the process parameters of the preceding modules based on the quality data fed back by the online detection module.

[0007] Furthermore, it also includes a wire pretreatment module, which is located between the automatic feeding module and the horizontal winding forming module. It is used to perform surface degreasing and cleaning, multi-roller straightening and smoothing treatment, and online detection of micro-defects in the insulation layer on the wire before it enters the winding station. This module includes an ultrasonic cleaning tank, multiple sets of straightening pressure rollers arranged in a staggered manner, and an insulation layer defect detection sensor based on the eddy current detection principle. It marks the location of the detected micro-defects in the insulation layer and records the defect coordinate data.

[0008] Furthermore, it also includes a defective product sorting and quality traceability module, which is set behind the online detection module. It is used to receive non-conforming products determined by the online detection module and automatically classify and sort them according to the defect category. Reworkable products are sent to the rework processing channel via the rework conveyor belt, and non-reworkable products are sent to the waste collection box. At the same time, the defect type code, defect location information, corresponding process parameter snapshot and timestamp data of each non-conforming product are automatically entered into the product quality traceability database.

[0009] Furthermore, the multi-stage tension adaptive adjustment device in the automatic feeding module includes an inlet tension wheel, an intermediate energy storage swing rod, an outlet tension wheel, and a servo tension controller. The wire passes through the inlet tension wheel, the intermediate energy storage swing rod, and the outlet tension wheel in sequence. The angular displacement sensor of the intermediate energy storage swing rod detects the swing angle of the swing rod in real time and converts it into the actual tension value of the wire. The servo tension controller compares the actual tension value with the preset target tension setting value and outputs a control signal to adjust the speed of the pay-off reel servo motor. When the winding speed changes, the tension fluctuation of the wire is controlled within the preset tension tolerance range.

[0010] Furthermore, the precision wire laying mechanism in the horizontal winding forming module includes a transversely moving ball screw pair, a wire laying guide wheel assembly, and a stepper drive motor. The wire laying guide wheel assembly is mounted on the slide of the transversely moving ball screw pair. The stepper drive motor drives the ball screw to rotate through a coupling, causing the wire laying guide wheel assembly to move axially along the magnetic core blank. After each turn of wire is wound, the stepper drive motor drives the wire laying guide wheel assembly to move laterally by a distance of one wire diameter, so that adjacent turns of wire are closely fitted and arranged. The horizontal spindle drive mechanism includes a spindle servo motor, a reducer, a spindle angle encoder, and a pneumatic clamping assembly. The spindle servo motor drives the spindle to rotate through the reducer. The spindle angle encoder provides real-time feedback on the spindle rotation angle to achieve accurate measurement of the number of winding turns. The pneumatic clamping assembly is used to clamp and fix the magnetic core blank.

[0011] Furthermore, the tension closed-loop feedback mechanism in the horizontal winding forming module continuously monitors the wire tension during the winding process and adjusts the damping torque of the pay-off reel in real time using the compensation amount calculated by the following formula: ;in This is the compensation amount for the damping torque of the wire feeding reel. This is the proportional gain coefficient. This is the measured tension value of the wire. To preset the target tension value of the winding, This is the differential gain coefficient.

[0012] Furthermore, the insulation layer circumferential cutting and stripping operation in the terminal forming and connection module is performed by a precision circumferential cutting and stripping mechanism. This mechanism includes two sets of V-shaped circumferential cutting blades arranged symmetrically on the upper and lower sides, a blade radial feed servo mechanism, and an adjustable stripping length limit stop. The V-shaped circumferential cutting blades, driven by the blade radial feed servo mechanism, cut into the insulation layer radially along the lead wire to a preset depth and then stop feeding. Subsequently, the wire clamping mechanism retracts axially to completely peel the cut insulation layer from the wire core to expose the bare wire end of a predetermined length.

[0013] Furthermore, the dimensional calibration operation in the shape shaping and encapsulation module is performed by a precision mold closing and shaping mechanism. This mechanism includes an upper forming mold, a lower forming mold, and a hydraulic servo drive component. The hydraulic servo drive component pushes the upper forming mold to move towards the lower forming mold to perform a mold closing action to correct and compress the dimensional shape of the inductor semi-finished product. The displacement sensor embedded in the lower forming mold detects the mold closing gap in real time. When the mold closing gap reaches the preset gap target value, the hydraulic servo drive component stops pressurizing and holds the pressure for a preset time before opening the mold to release the product.

[0014] Furthermore, the inductance measurement in the online testing module uses an LCR digital bridge to measure the inductance value of the inductor product through a four-terminal test fixture under preset test frequency and preset test voltage conditions. The DC resistance measurement uses a four-wire Kelvin test method to eliminate the influence of the test lead resistance on the measurement results. The inter-turn insulation withstand voltage test uses a pulse-type inter-turn short-circuit tester to apply a high-voltage pulse of preset amplitude to the coil under test and compares the difference in the decaying oscillation waveform between the standard good coil and the coil under test to determine whether there is a short-circuit fault in the inter-turn insulation. The visual inspection of appearance defects uses an industrial camera array arranged at multiple angles to acquire multi-directional surface images of the inductor product and uses a deep learning visual recognition algorithm to detect pin misalignment, encapsulation layer cracks, and surface foreign matter adhesion defects.

[0015] Furthermore, the central control module includes an industrial control computer, a programmable logic controller (PLC), and a distributed remote input / output module. The industrial control computer runs host computer monitoring and management software for centralized setting and modification of process formula parameters, statistical process control analysis and graphical display of quality inspection data, and storage and retrieval of production process logs. The PLC communicates in real time with the servo drivers, sensors, and actuators of each module through the distributed remote input / output module. The PLC internally runs a self-tuning process parameter optimization algorithm, which automatically calculates and updates the process parameter correction values ​​of each preceding module based on the quality deviation data fed back by the online detection module.

[0016] Compared with existing technologies, the beneficial effects of this invention are: This system realizes fully automated continuous operation of horizontal inductors from raw material supply to finished product inspection and sorting. No manual operation or material transfer is required between each process, which reduces product quality deviation caused by human factors and avoids accidental damage such as bumps and scratches to magnetic cores and semi-finished products during manual transfer.

[0017] The multi-stage tension adaptive adjustment device of the automatic feeding module can adjust the damping torque in real time according to the wire feeding speed to maintain stable wire tension and avoid problems such as wire breakage and uneven coil tension caused by tension fluctuations during winding. The precision wire arrangement mechanism of the horizontal winding forming module can ensure that the turns are neatly arranged and the tension of each layer of winding is consistent during the winding process, improving the consistency of the electrical performance of the coil winding and reducing performance deviations caused by winding problems.

[0018] The circumferential stripping structure of the terminal forming and connection module can strip the insulation layer without damaging the internal wire core. The operating parameters of the terminal connection process are controllable, ensuring the reliability of the connection between the lead wire and the terminal and reducing the problem of unstable contact resistance. The shape shaping and encapsulation module can ensure that the finished inductor has uniform dimensions, the lead bending angle meets the requirements, and the outer insulation protective layer has uniform thickness, improving the product's structural consistency and insulation protection performance.

[0019] The online inspection module performs comprehensive testing on the electrical performance and appearance of all finished products, preventing defective products from leaving the factory. The central control module centrally manages the operation of all modules and automatically adjusts the process parameters of preceding processes based on the product quality data obtained from the tests, forming a closed-loop quality control throughout the entire production process and continuously improving product quality stability. The defective product sorting and quality traceability module classifies defective products according to defect type and retains the corresponding production process data, facilitating subsequent quality problem investigation and process optimization. Attached Figure Description

[0020] Figure 1 This is a flowchart of the overall process flow of the system proposed in this invention; Figure 2 This is a flowchart of the automatic feeding and wire pretreatment process proposed in this invention; Figure 3 This is a flowchart of the horizontal winding forming and precision wire arrangement control proposed in this invention; Figure 4 This is a flowchart of the terminal forming connection and shape shaping and encapsulation control proposed in this invention; Figure 5 This is a flowchart of the online detection and closed-loop self-tuning optimization control proposed in this invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Reference Figures 1 to 5 This invention discloses a fully automated horizontal inductor forming system, comprising the following modules: The automatic feeding module is used to transport the winding wire from the pay-off reel to the winding station via a multi-stage tension adaptive adjustment device. At the same time, the magnetic core blanks are oriented and separated one by one by a vibratory feeder and then transported to the magnetic core assembly station via a linear feeding track. The multi-stage tension adaptive adjustment device adjusts the damping torque in real time according to the wire conveying speed to maintain constant wire tension. The horizontal winding forming module is located behind the automatic feeding module. It is used to precisely wind the wire into the magnetic core blank in the horizontal direction according to the preset number of turns, layers and winding pitch to form a coil winding. The module includes a horizontal spindle drive mechanism, a precision wire laying mechanism, a tension closed-loop feedback mechanism and a turn metering and interlayer switching control mechanism. The terminal forming and connection module is located behind the horizontal winding forming module. It is used to perform fixed-length cutting, insulation layer ring cutting and peeling, and crimping or resistance welding operations on the lead wire ends of the coil winding and the terminal to form a reliable electrical connection with low contact resistance between the lead wire ends and the terminal. The shape shaping and encapsulation module is located behind the terminal forming and connection module. It is used to perform shape and size calibration, pin bending and shaping, and to encapsulate the inductor semi-finished product with an insulating protective layer through injection molding or impregnation to form the final product shape. The online testing module, located behind the shape-forming and encapsulation module, is used to measure the inductance, DC resistance, inter-turn insulation withstand voltage test, and visually inspect the appearance defects of the formed inductor products. It also compares the test data with preset quality standard thresholds to determine whether the product is qualified. The central control module is connected to each of the above modules via an industrial fieldbus. It is used to centrally set the operating parameters of each module, monitor the operating status in real time, and record and store data. Based on the quality data fed back by the online detection module, it automatically adjusts the process parameters of the preceding modules to achieve closed-loop quality control of the entire production process.

[0023] The invention also includes a wire pretreatment module, which is located between the automatic feeding module and the horizontal winding forming module. This module is used to sequentially perform surface degreasing and cleaning, multi-roller straightening and smoothing treatment, and online detection of micro-defects in the insulation layer on the wire before it enters the winding station. The module includes an ultrasonic cleaning tank, multiple sets of straightening pressure rollers arranged in a staggered manner, and an insulation layer defect detection sensor based on the eddy current detection principle. The module marks the location of the detected micro-defects in the insulation layer and records the defect coordinate data.

[0024] This invention also includes a defective product sorting and quality traceability module, which is located behind the online detection module. It is used to receive non-conforming products determined by the online detection module and automatically classify and divert them according to the defect category. Reworkable products are sent to the rework processing channel via the rework conveyor belt, and non-reworkable products are sent to the waste collection box. At the same time, the defect type code, defect location information, corresponding process parameter snapshot and timestamp data of each non-conforming product are automatically entered into the product quality traceability database.

[0025] In this invention, the multi-stage tension adaptive adjustment device in the automatic feeding module includes an inlet tension wheel, an intermediate energy storage swing rod, an outlet tension wheel, and a servo tension controller. The wire passes through the inlet tension wheel, the intermediate energy storage swing rod, and the outlet tension wheel in sequence. The angular displacement sensor of the intermediate energy storage swing rod detects the swing angle of the swing rod in real time and converts it into the actual tension value of the wire. The servo tension controller compares the actual tension value with the preset target tension setting value and outputs a control signal to adjust the speed of the pay-off reel servo motor. When the winding speed changes, the tension fluctuation of the wire is controlled within the preset tension tolerance range.

[0026] In this invention, the precision wire-laying mechanism in the horizontal winding forming module includes a transversely moving ball screw pair, a wire-laying guide wheel assembly, and a stepper drive motor. The wire-laying guide wheel assembly is mounted on the slide of the transversely moving ball screw pair. The stepper drive motor drives the ball screw to rotate through a coupling, causing the wire-laying guide wheel assembly to translate axially along the magnetic core blank. After each turn of wire is wound, the stepper drive motor drives the wire-laying guide wheel assembly to move laterally by a distance of one wire diameter, so that adjacent turns of wire are tightly fitted together. The horizontal spindle drive mechanism includes a spindle servo motor, a reducer, a spindle angle encoder, and a pneumatic clamping assembly. The spindle servo motor drives the spindle to rotate through the reducer. The spindle angle encoder provides real-time feedback of the spindle rotation angle to achieve accurate measurement of the number of winding turns. The pneumatic clamping assembly is used to clamp and fix the magnetic core blank.

[0027] In this invention, the tension closed-loop feedback mechanism in the horizontal winding forming module continuously monitors the wire tension during the winding process and adjusts the damping torque of the pay-off reel in real time using the compensation amount calculated by the following formula: ;in This refers to the damping torque compensation of the wire feeding reel, expressed in Newton-meters (N·m). This is the proportional gain coefficient, measured in Newton-meters per Newton. The measured tension value of the wire is expressed in Newtons. The preset target tension value for winding, in Newtons; The differential gain coefficient is expressed in Newton-meter-seconds per Newton. This compensation is used to quickly suppress tension disturbances caused by the acceleration or deceleration of the winding speed during the winding process, ensuring that the tightness between each turn of the coil winding is uniform and consistent, and controlling the tightness of the coil winding within the preset quality range.

[0028] In this invention, the insulation layer circumferential cutting and stripping operation in the terminal forming and connection module is performed by a precision circumferential cutting and stripping mechanism. This mechanism includes two sets of V-shaped circumferential cutting blades arranged symmetrically, a blade radial feed servo mechanism, and an adjustable stripping length limit stop. The V-shaped circumferential cutting blades, driven by the blade radial feed servo mechanism, cut into the insulation layer radially along the lead wire to a preset depth and then stop feeding. Subsequently, the wire clamping mechanism retracts axially to completely peel the cut insulation layer from the wire core, exposing a bare wire end of a predetermined length. The crimping operation between the bare wire end and the terminal is performed by a servo crimping mechanism. The servo crimping mechanism has built-in pressure and displacement sensors, which simultaneously monitor the crimping force and crimping displacement during the crimping process. When the crimping force reaches the preset crimping termination force and the crimping displacement is within the preset displacement window, the crimping is deemed qualified.

[0029] In this invention, the dimensional calibration operation in the shape shaping and encapsulation module is performed by a precision mold closing and shaping mechanism. This mechanism includes an upper forming mold, a lower forming mold, and a hydraulic servo drive component. The hydraulic servo drive component pushes the upper forming mold to move towards the lower forming mold to perform a mold closing action to correct and compress the dimensional shape of the inductor semi-finished product. A displacement sensor embedded in the lower forming mold detects the mold closing gap in real time. When the mold closing gap reaches the preset gap target value, the hydraulic servo drive component stops pressurizing and holds the pressure for a preset time before opening the mold to release the product. The pin bending and shaping operation is performed by a pin bending mechanism. This mechanism includes an adjustable angle bending mold and a bending drive cylinder. The bending drive cylinder pushes the adjustable angle bending mold to bend the pin to a preset tilt angle in one go.

[0030] In this invention, the inductance measurement in the online testing module uses an LCR digital bridge to measure the inductance value of the inductor product through a four-terminal test fixture under preset test frequency and preset test voltage conditions. The DC resistance measurement uses a four-wire Kelvin test method to eliminate the influence of the test lead resistance on the measurement results. The inter-turn insulation withstand voltage test uses a pulse-type inter-turn short-circuit tester to apply a high-voltage pulse of preset amplitude to the coil under test and compares the difference in the decaying oscillation waveform between the standard good coil and the coil under test to determine whether there is a short-circuit fault in the inter-turn insulation. The visual inspection of appearance defects uses an industrial camera array arranged at multiple angles to acquire multi-directional surface images of the inductor product and uses a deep learning visual recognition algorithm to detect pin misalignment, encapsulation layer cracks, and surface foreign matter adhesion defects.

[0031] In this invention, the central control module includes an industrial control computer, a programmable logic controller (PLC), and a distributed remote input / output module. The industrial control computer runs host computer monitoring and management software for centralized setting and modification of process formula parameters, statistical process control analysis and graphical display of quality inspection data, and storage and retrieval of production process logs. The PLC communicates in real time with the servo drivers, sensors, and actuators of each module through the distributed remote input / output module. The PLC runs a self-tuning process parameter optimization algorithm. The self-tuning process parameter optimization algorithm automatically calculates and updates the process parameter correction values ​​of each preceding module based on the quality deviation data fed back by the online detection module, forming a closed-loop quality continuous improvement control loop from detection feedback to process adjustment to re-detection.

[0032] Example 1

[0033] Before production starts, operators enter the corresponding product's process formula parameters into the host computer monitoring and management software of the central control module, including the target value of wire tension, number of winding turns, number of layers, winding pitch, stripping length, crimping force threshold, target value of mold closing gap, holding time, pin bending angle, and standard threshold values ​​for various performance tests. The parameters are then simultaneously sent to the execution units of each module.

[0034] After production starts, the automatic feeding module activates. The enameled wire on the pay-off reel is sequentially fed to the winding station via the inlet tension wheel, the intermediate energy storage swing arm, and the outlet tension wheel. The angular displacement sensor on the intermediate energy storage swing arm collects the swing angle of the swing arm in real time and converts it into the actual tension value of the wire. The servo tension controller compares the actual tension value with the preset target tension value and outputs a control signal to adjust the speed of the pay-off reel servo motor, controlling the wire tension fluctuation within the preset tolerance range when the winding speed changes. At the same time, the magnetic core blanks are fed into the vibratory feeder. The vibratory feeder arranges the magnetic core blanks in a preset orientation through directional vibration, separates them one by one, and sends them into the linear feeding track to be transported to the magnetic core assembly station.

[0035] Before being conveyed to the winding station, the wire passes through a wire pretreatment module. First, it enters an ultrasonic cleaning tank, where ultrasonic vibrations remove oil and impurities from the wire surface. Then, it passes through multiple sets of straightening rollers arranged in a staggered manner. The rollers apply a preset pressure force to straighten and smooth the bent parts of the wire. After that, it passes through an insulation layer defect detection sensor based on the eddy current detection principle. The sensor scans the insulation layer on the surface of the wire, marks the location of the detected micro-defects, and records the coordinate data of the defects simultaneously. The marked defective sections of wire are automatically rejected in the subsequent winding process and do not enter the winding stage.

[0036] The pre-processed wire is fed into the horizontal winding forming module. The pneumatic clamping assembly at the core assembly station clamps and fixes the delivered core blank to the end of the spindle. The spindle servo motor drives the spindle to rotate horizontally through the reducer. The spindle angle encoder provides real-time feedback on the spindle's rotation angle and measures the number of turns wound.

[0037] The stepper motor of the precision wire winding mechanism drives the lateral ball screw pair to rotate via a coupling, which in turn drives the wire winding guide wheel assembly mounted on the slide to translate axially along the magnetic core blank. After each turn of wire is wound, the stepper motor drives the wire winding guide wheel assembly to move laterally by one wire diameter, ensuring that adjacent turns of wire are tightly packed together. After completing a single layer of winding, the interlayer position is automatically switched to begin the winding of the next layer. During the winding process, the tension closed-loop feedback mechanism continuously monitors the wire tension and adjusts the damping torque of the pay-off reel in real time to suppress tension disturbances during the acceleration and deceleration of the winding, ensuring that the tightness of each turn of the coil winding is uniform and that the winding tightness is maintained within a preset range.

[0038] The completed coil winding is transferred to the terminal forming and connection module. First, the two lead wire ends of the coil are cut to a fixed length. Then, the upper and lower V-shaped circumferential cutting blades of the precision circumferential cutting and stripping mechanism are driven by the blade radial feed servo mechanism to cut into the insulation layer along the lead wire radially to a preset depth and then stop feeding. The wire clamping mechanism retracts axially, so that the cut insulation layer is completely peeled off from the wire core, exposing the bare wire end of the preset length.

[0039] The terminal block is then conveyed to the crimping station. The servo crimping mechanism moves downward to crimp the bare wire end and the terminal block. The pressure sensor and displacement sensor built into the servo crimping mechanism collect the crimping force and crimping displacement in real time. When the crimping force reaches the preset crimping termination force and the crimping displacement is within the preset displacement window, the crimping is deemed qualified.

[0040] The inductor semi-finished product with completed terminal connections is transferred to the shape shaping and encapsulation module. It is first sent into the lower forming mold of the precision mold closing and shaping mechanism. The hydraulic servo drive component pushes the upper forming mold to move towards the lower forming mold, and performs the mold closing action to correct and compress the shape and size of the inductor semi-finished product. The displacement sensor embedded in the lower forming mold detects the mold closing gap in real time. When the mold closing gap reaches the preset gap target value, the hydraulic servo drive component stops pressurizing. After holding the pressure for a preset time, the mold is opened and the product is released.

[0041] The semi-finished product is then sent to the pin bending station, where the bending drive cylinder of the pin bending mechanism pushes the adjustable angle bending die to bend the pin to the preset tilt angle in one go. The shaped semi-finished product is then sent to the injection molding station, where an insulating protective layer is wrapped around it by injection molding to form the final product shape.

[0042] After molding, the product is conveyed to the online testing module. First, an LCR digital bridge is connected via a four-terminal test fixture. The inductance is measured under preset test frequency and voltage conditions. Then, the DC resistance is measured using a four-wire Kelvin test method. Next, a high-voltage pulse of preset amplitude is applied to the tested coil using a pulse-type inter-turn short-circuit tester. The difference in the damped oscillation waveform between the standard good coil and the tested coil is compared to determine if a short-circuit fault exists in the inter-turn insulation. The product is then sent to the vision inspection station. An array of industrial cameras arranged at multiple angles acquires multi-directional surface images of the product. Deep learning visual recognition algorithms detect defects such as pin misalignment, encapsulation cracks, and surface foreign matter adhesion. All test data is compared with preset quality standard thresholds to determine product qualification.

[0043] Products that have completed inspection are transported to the defective product sorting and quality traceability module. Products deemed non-conforming are sorted out and categorized according to defect type. Reworkable products are sent to the rework processing channel via a rework conveyor belt, while non-reworkable products are sent to the waste collection bin. The defect type code, defect location information, corresponding process parameter snapshot, and timestamp data for each non-conforming product are automatically entered into the product quality traceability database. The industrial control computer in the central control module records and stores all production data, performs statistical process control analysis, and displays the analysis results graphically. The programmable logic controller communicates in real time with the servo drives, sensors, and actuators of each module through distributed remote input / output modules. The internally running self-tuning process parameter optimization algorithm automatically calculates and updates the process parameter correction values ​​of each preceding module based on the quality deviation data fed back by the online inspection module, forming a closed-loop continuous quality improvement control loop of inspection feedback, process adjustment, and re-inspection.

[0044] This embodiment achieves fully automated operation for the production of low-power horizontal inductors, with smooth transitions between processes requiring no manual intervention, effectively reducing consistency deviations caused by human operation. Multi-level tension adjustment and precision wiring structure ensure uniform and stable coil windings, controllable terminal crimping parameters guarantee connection reliability, comprehensive testing covers the electrical performance and appearance quality of all products, closed-loop control logic continuously optimizes process parameters based on test data, and a quality traceability system quickly locates the source of problems. Overall, it is adapted to the large-scale production needs of low-power inductors, and the product's performance stability and structural reliability meet the requirements of downstream applications.

[0045] Example 2

[0046] Before production starts, operators enter the corresponding product's process formula parameters into the host computer monitoring and management software of the central control module. These parameters include the target tension value for large-diameter wires, lower winding speed, more winding layers, stripping depth for thick wires, resistance welding current and duration parameters, greater mold closing pressure, immersion and encapsulation temperature and duration parameters, and corresponding performance testing thresholds. These parameters are then simultaneously sent to the execution units of each module.

[0047] After production starts, the automatic feeding module activates. The flat enameled wire on the pay-off reel is sequentially fed to the winding station via the inlet tension wheel, the intermediate energy storage swing rod, and the outlet tension wheel. The angular displacement sensor of the intermediate energy storage swing rod collects the swing angle in real time and converts it into the actual tension value of the wire. The servo tension controller compares the actual tension value with the preset target tension value and outputs a control signal to adjust the speed of the pay-off reel servo motor, keeping the tension fluctuation within the preset tolerance range during the winding acceleration and deceleration process. The magnetic core blanks are fed into the vibratory feeder. The vibratory feeder arranges the large magnetic core blanks in a preset orientation through directional vibration, separates them one by one, and sends them to the heavy-duty linear feeding track, which transports them to the magnetic core assembly station.

[0048] Before being conveyed to the winding station, the wire passes through a wire pretreatment module. First, it enters an ultrasonic cleaning tank to remove rolling oil and dust impurities from the wire surface. Then, it passes through multiple sets of high-pressure straightening rollers arranged in a staggered manner to apply matching pressure to the flat wire, eliminating the coiling stress and straightening and smoothing the wire. After that, it passes through an insulation layer defect detection sensor based on the eddy current detection principle to scan the insulation layer on the wire surface, mark the location of detected micro-defects such as pinholes and bumps, and record the defect coordinate data simultaneously. The defective section of wire is automatically rejected in the subsequent winding process.

[0049] The pre-processed wire is fed into the horizontal winding forming module. The high-clamping force pneumatic clamping assembly at the core assembly station clamps and fixes the delivered core blank to the end of the spindle. The high-torque spindle servo motor drives the spindle to rotate horizontally through the reducer. The spindle angle encoder provides real-time feedback on the spindle rotation angle and accurately measures the number of turns wound.

[0050] The high-torque stepper motor of the precision wire winding mechanism drives the heavy-duty lateral moving ball screw pair to rotate via a coupling. This drives the wide-slot wire winding guide wheel assembly mounted on the slide to translate axially along the magnetic core blank. After each turn of flat wire is wound, the stepper motor drives the wire winding guide wheel assembly to move laterally a distance equal to the width of the flat wire, ensuring that adjacent turns of wire are tightly packed together. After completing a single layer of winding, the interlayer position is automatically switched to begin the next layer of winding. During the winding process, the tension closed-loop feedback mechanism continuously monitors the wire tension and adjusts the damping torque of the pay-off reel in real time to suppress tension disturbances during the acceleration and deceleration of the winding, ensuring that the tightness of each turn of the coil winding is uniform and that the winding tension is maintained within a preset range.

[0051] The completed coil winding is transferred to the terminal forming and connection module. First, the two lead ends of the coil are cut to a fixed length. Then, the upper and lower sets of V-shaped circumferential cutting blades of the precision circumferential cutting and stripping mechanism, driven by the blade radial feed servo mechanism, cut into the insulation layer along the lead ends radially to a preset depth and then stop feeding. The wire clamping mechanism retracts axially, so that the cut insulation layer is completely peeled off from the wire core, exposing the bare wire end of the preset length. After that, the terminal is transported to the resistance welding station. The resistance welding mechanism applies a preset current and pressure to the connection part of the bare wire end and the terminal to complete the resistance welding. During the welding process, the welding current and welding pressure are monitored in real time. When the parameters meet the preset range, the welding is judged to be qualified.

[0052] The inductor semi-finished product with completed terminal connections is transferred to the shaping and encapsulation module. First, it is fed into the high-strength lower forming mold of the precision mold-closing and shaping mechanism. A hydraulic servo drive component pushes the upper forming mold towards the lower forming mold, performing a mold-closing action to correct and compress the dimensions of the inductor semi-finished product. A displacement sensor embedded in the lower forming mold monitors the mold-closing gap in real time. When the gap reaches the preset target value, the hydraulic servo drive component stops pressurizing, and after holding the pressure for a preset time, the mold opens to release the product. The semi-finished product is then sent to the lead bending station. The high-thrust bending drive cylinder of the lead bending mechanism pushes the adjustable-angle bending mold, bending the thick leads to the preset tilt angle in one go. The shaped semi-finished product is then sent to the impregnation station, where an insulating protective layer is coated onto the outside of the semi-finished product through impregnation. After drying, the final product shape is formed.

[0053] After molding, the product is conveyed to the online testing module. First, an LCR digital bridge is connected to the high-current four-terminal test fixture. The inductance is measured under preset test frequency and voltage conditions. Then, the DC resistance is measured using a high-current four-wire Kelvin test method. Next, a high-voltage pulse of preset amplitude is applied to the tested coil using a pulse-type inter-turn short-circuit tester. The difference in the damped oscillation waveform between the standard good coil and the tested coil is compared to determine if a short-circuit fault exists in the inter-turn insulation. The product is then sent to the vision inspection station. A high-resolution industrial camera array arranged at multiple angles acquires multi-directional surface images of the product. Deep learning visual recognition algorithms detect defects such as pin misalignment, encapsulation cracks, and surface foreign matter adhesion. All test data is compared with preset quality standard thresholds to determine product qualification.

[0054] Products that have completed inspection are transported to the defective product sorting and quality traceability module. Products deemed non-conforming are sorted out and categorized according to defect type. Reworkable products are sent to the rework processing channel via a rework conveyor belt, while non-reworkable products are sent to the waste collection bin. The defect type code, defect location information, corresponding process parameter snapshot, and timestamp data for each non-conforming product are automatically entered into the product quality traceability database. The industrial control computer in the central control module records and stores all production data, performs statistical process control analysis, and displays the analysis results graphically. The programmable logic controller communicates in real time with the servo drives, sensors, and actuators of each module through distributed remote input / output modules. The internally running self-tuning process parameter optimization algorithm automatically calculates and updates the process parameter correction values ​​of each preceding module based on the quality deviation data fed back by the online inspection module, forming a closed-loop continuous quality improvement control loop of inspection feedback, process adjustment, and re-inspection.

[0055] This embodiment achieves fully automated operation for the production of high-current horizontal inductors, adapting to the processing requirements of large-diameter flat wires and large-size magnetic cores. The execution units of each process are matched to the structural characteristics of high-current inductors, avoiding deformation and damage during the processing of large-size components. Tension control and wiring structure are adapted to the requirements of flat wire winding, ensuring tight, gapless winding fit. Resistance welding connection method adapts to high-current conduction requirements. Full-scale testing covers all performance parameters under high-current conditions. Closed-loop control and quality traceability systems ensure product consistency and traceability, comprehensively meeting the production requirements of high-current energy storage inductors. The product's current-carrying capacity and structural reliability meet the usage standards of downstream application scenarios.

[0056] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A fully automated horizontal inductor molding system, characterized in that, Includes the following modules: The automatic feeding module is used to transport the winding wire from the pay-off reel to the winding station via a multi-stage tension adaptive adjustment device. At the same time, the magnetic core blanks are oriented and separated one by one by a vibratory feeder and then transported to the magnetic core assembly station via a linear feeding track. The horizontal winding forming module is located behind the automatic feeding module. It is used to precisely wind the wire into the magnetic core blank in the horizontal direction according to the preset number of turns, layers and winding pitch to form a coil winding. The module includes a horizontal spindle drive mechanism, a precision wire laying mechanism, a tension closed-loop feedback mechanism and a turn metering and interlayer switching control mechanism. The terminal forming and connection module is located behind the horizontal winding forming module. It is used to perform fixed-length cutting, insulation layer ring cutting and peeling, and crimping or resistance welding operations on the lead wire ends of the coil winding and the terminal to form a reliable electrical connection with low contact resistance between the lead wire ends and the terminal. The shape shaping and encapsulation module is located behind the terminal forming and connection module. It is used to perform shape and size calibration, pin bending and shaping, and to encapsulate the inductor semi-finished product with an insulating protective layer through injection molding or impregnation to form the final product shape. The online testing module, located behind the shape-forming and encapsulation module, is used to measure the inductance, DC resistance, inter-turn insulation withstand voltage test, and visually inspect the appearance defects of the formed inductor products. It also compares the test data with preset quality standard thresholds to determine whether the product is qualified. The central control module is connected to each of the above modules via an industrial fieldbus. It is used to centrally set the operating parameters of each module, monitor the operating status in real time, and record and store data. It also automatically adjusts the process parameters of the preceding modules based on the quality data fed back by the online detection module.

2. The horizontal inductor fully automated molding system according to claim 1, characterized in that, Also includes: The wire pretreatment module is located between the automatic feeding module and the horizontal winding forming module. It is used to perform surface degreasing and cleaning, multi-roller straightening and smoothing treatment, and online detection of micro-defects in the insulation layer on the wire before it enters the winding station. The module includes an ultrasonic cleaning tank, multiple sets of straightening pressure rollers arranged in a staggered manner, and insulation layer defect detection sensors based on the eddy current detection principle. The module marks the location of the detected micro-defects in the insulation layer and records the defect coordinate data.

3. The fully automated horizontal inductor molding system according to claim 1, characterized in that, Also includes: The defective product sorting and quality traceability module is located behind the online inspection module. It receives non-conforming products identified by the online inspection module and automatically classifies and sorts them according to the defect category. Reworkable products are sent to the rework processing channel via the rework conveyor belt, while non-reworkable products are sent to the waste collection bin. At the same time, the defect type code, defect location information, corresponding process parameter snapshot, and timestamp data of each non-conforming product are automatically entered into the product quality traceability database.

4. The fully automated horizontal inductor molding system according to claim 1, characterized in that, The multi-stage tension adaptive adjustment device in the automatic feeding module includes an inlet tension wheel, an intermediate energy storage swing rod, an outlet tension wheel, and a servo tension controller. The wire passes through the inlet tension wheel, the intermediate energy storage swing rod, and the outlet tension wheel in sequence. The angular displacement sensor of the intermediate energy storage swing rod detects the swing angle of the swing rod in real time and converts it into the actual tension value of the wire. The servo tension controller compares the actual tension value with the preset target tension setting value and outputs a control signal to adjust the speed of the pay-off reel servo motor. When the winding speed changes, the tension fluctuation of the wire is controlled within the preset tension tolerance range.

5. The fully automated horizontal inductor molding system according to claim 1, characterized in that, The precision wire laying mechanism in the horizontal winding forming module includes a transversely moving ball screw pair, a wire laying guide wheel assembly, and a stepper drive motor. The wire laying guide wheel assembly is mounted on the slide of the transversely moving ball screw pair. The stepper drive motor drives the ball screw to rotate through a coupling, causing the wire laying guide wheel assembly to move axially along the magnetic core blank. After each turn of wire is wound, the stepper drive motor drives the wire laying guide wheel assembly to move laterally by a wire diameter, so that adjacent turns of wire are closely fitted and arranged. The horizontal spindle drive mechanism includes a spindle servo motor, a reducer, a spindle angle encoder, and a pneumatic clamping assembly. The spindle servo motor drives the spindle to rotate through the reducer. The spindle angle encoder provides real-time feedback on the spindle rotation angle to achieve accurate measurement of the number of winding turns. The pneumatic clamping assembly is used to clamp and fix the magnetic core blank.

6. The fully automated horizontal inductor molding system according to claim 5, characterized in that, The tension closed-loop feedback mechanism in the horizontal winding forming module continuously monitors the wire tension during the winding process and adjusts the damping torque of the pay-off reel in real time through a compensation amount calculated by the following formula: ;in This is the compensation amount for the damping torque of the wire feeding reel. This is the proportional gain coefficient. This is the measured tension value of the wire. To preset the target tension value of the winding, This is the differential gain coefficient.

7. The fully automated horizontal inductor molding system according to claim 1, characterized in that, The insulation layer circumferential cutting and stripping operation in the terminal forming and connection module is performed by a precision circumferential cutting and stripping mechanism. This mechanism includes two sets of V-shaped circumferential cutting blades arranged symmetrically on the upper and lower sides, a blade radial feed servo mechanism, and an adjustable stripping length limit stop. The V-shaped circumferential cutting blades, driven by the blade radial feed servo mechanism, cut into the insulation layer radially along the lead wire to a preset depth and then stop feeding. Subsequently, the wire clamping mechanism retracts axially to completely peel the cut insulation layer from the wire core to expose the bare wire end of a predetermined length.

8. The fully automated horizontal inductor molding system according to claim 1, characterized in that, The dimensional calibration operation in the shape shaping and encapsulation module is performed by a precision mold closing and shaping mechanism. This mechanism includes an upper forming mold, a lower forming mold, and a hydraulic servo drive component. The hydraulic servo drive component pushes the upper forming mold to move towards the lower forming mold to perform a mold closing action to correct and compress the dimensional shape of the inductor semi-finished product. The displacement sensor embedded in the lower forming mold detects the mold closing gap in real time. When the mold closing gap reaches the preset gap target value, the hydraulic servo drive component stops pressurizing and holds the pressure for a preset time before opening the mold to release the product.

9. The fully automated horizontal inductor molding system according to claim 1, characterized in that, The inductance measurement in the online testing module uses an LCR digital bridge to measure the inductance value of the inductor product through a four-terminal test fixture under preset test frequency and preset test voltage conditions. The DC resistance measurement uses a four-wire Kelvin test method to eliminate the influence of the test lead resistance on the measurement results. The inter-turn insulation withstand voltage test uses a pulse-type inter-turn short-circuit tester to apply a high-voltage pulse of preset amplitude to the coil under test and compares the difference in the decaying oscillation waveform between the standard good coil and the coil under test to determine whether there is a short-circuit fault in the inter-turn insulation. The visual inspection of appearance defects uses an industrial camera array arranged at multiple angles to acquire multi-directional surface images of the inductor product and uses a deep learning visual recognition algorithm to detect pin misalignment, encapsulation layer cracks and surface foreign matter adhesion defects.

10. The fully automated horizontal inductor molding system according to claim 1, characterized in that, The central control module includes an industrial control computer, a programmable logic controller (PLC), and a distributed remote input / output module. The industrial control computer runs host computer monitoring and management software for centralized setting and modification of process formula parameters, statistical process control analysis and graphical display of quality inspection data, and storage and retrieval of production process logs. The PLC communicates in real time with the servo drivers, sensors, and actuators of each module through the distributed remote input / output module. The PLC runs a self-tuning process parameter optimization algorithm, which automatically calculates and updates the process parameter correction values ​​of each preceding module based on the quality deviation data fed back by the online detection module.

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