T-core winding and powder filling integrated preparation process and integrated tool system

Abstract

This invention discloses an integrated manufacturing process and integrated chemical loading system for T-core winding and powder filling, relating to the field of magnetic component manufacturing technology. It includes a workpiece clamping and rotation drive unit, an on-demand zoned powder supply execution unit, and a synchronous collaborative control center. The workpiece clamping and rotation drive unit is used to fix the magnetic core and drive its rotation for winding. The on-demand zoned powder supply execution unit is integrated next to the clamping unit and is used to directionally inject powder into the winding gap during the winding process. The synchronous collaborative control center dynamically adjusts the powder supply rate and timing based on the winding progress and rotation speed data, forming a synchronous closed-loop control for winding and powder filling. This application can realize continuous integrated manufacturing from magnetic core clamping and winding to powder filling, eliminating the need for intermediate transfers. It effectively solves the problems of low efficiency, poor connection, and uneven powder filling caused by process separation, improving product consistency and production efficiency.

Description

Technical Field

[0001] This invention relates to the field of magnetic component manufacturing technology, specifically to a T-core wire-wound powder-filling integrated preparation process and integrated chemical equipment system. Background Technology

[0002] T-Core inductors, as a typical type of molded power inductor, are widely used in electronic systems with stringent requirements for space and electromagnetic performance, such as mobile terminals, wearable devices, and high-density power modules. Their structural feature is the use of a T-shaped cross-section magnetic core, combined with an embedded or wrap-around winding design, to achieve synergistic optimization of low DC resistance, high saturation current, and good high-frequency characteristics. At the manufacturing level, the mainstream process route for T-Core inductors typically includes three core processes: core prefabrication, wire winding assembly, and magnetic powder encapsulation. The magnetic core is mostly obtained by molding soft magnetic powder, while the wire winding relies on automated winding equipment to precisely arrange the conductors in specific areas of the magnetic core. Subsequent powder filling and curing require secondary infusion or vibration filling methods to achieve air gap control and structural reinforcement. In the existing technology, some solutions adopt a sequential process of first cold pressing the magnetic core and then winding the coil, while other solutions use hot pressing sintering process to replace the traditional combination. These process routes are all based on the step-by-step implementation paradigm, that is, the magnetic core forming, winding operation and powder packaging are completed independently in different work stations or equipment, and the process relies on manual transfer or robotic arm docking.

[0003] Existing manufacturing processes for T-core magnetic components generally face technical bottlenecks such as low efficiency, poor coordination, uneven powder filling, and limited automation due to the separation of winding and powder filling processes. Because winding and powder filling lack coordination mechanisms in space, time, and control dimensions, semi-finished products are prone to cumulative positioning errors during process transfer. Furthermore, it is difficult to dynamically adjust powder injection parameters based on the real-time geometry of the winding, resulting in significant gradient differences in powder density between winding gaps and interlayer transition zones. In addition, the lack of unified timing coordination and status feedback loops among the processes in a step-by-step process makes it difficult to achieve millisecond-level synchronous response between winding progress and powder filling actions. Multiple clamping and post-processing methods further limit the improvement of production line cycle time and the level of automation integration.

[0004] In summary, existing technologies are insufficient to meet the stringent requirements of high consistency, high volume, and miniaturized T-core inductors in terms of both manufacturing precision and efficiency. There is an urgent need for an integrated manufacturing process and system that can achieve coordinated spatial and temporal processes for wire winding and powder filling. Summary of the Invention

[0005] The purpose of this invention is to provide an integrated manufacturing process and chemical equipment system for T-core winding and powder filling, which effectively solves the problems of low efficiency, poor connection, uneven powder filling and limited automation caused by the separation of winding and powder filling processes in the existing manufacturing process of T-core magnetic components.

[0006] The present invention solves the above-mentioned technical problems through the following technical solution, and the present invention includes the following steps: A T-core wire-wound powder-filling integrated preparation process and integrated chemical equipment system, comprising: The workpiece clamping and rotation drive unit is configured to fix the T-core magnetic core to the rotation axis and drive it to rotate at a constant speed for coil winding; The on-demand zoned powder supply execution unit is integrated with the workpiece clamping and rotation drive unit. It includes multiple discharge interfaces and a power conveying mechanism arranged circumferentially along the magnetic core window. It is configured to inject directional powder into the winding gap according to preset logic during the winding process. The synchronous collaborative control center is connected to the workpiece clamping and rotation drive unit and the on-demand zoned powder supply execution unit, respectively. It has a built-in process parameter database and control algorithm and is configured to acquire winding progress and rotation speed data in real time. Through a preset mathematical model, it dynamically calculates and adjusts the powder supply rate and discharge sequence of the on-demand zoned powder supply execution unit to form a synchronous closed-loop control of winding and powder filling. This enables the system to complete continuous integrated manufacturing from magnetic core clamping, winding to powder filling without intermediate transfer.

[0007] Preferably, the workpiece clamping and rotation drive unit adopts an adjustable U-shaped clamp structure, with an elastic buffer layer on the inner wall of the clamp and fixed in contact with the outer surface of the T-core magnetic core; one end of the clamp integrates a wire guide groove, and the other end is connected to a servo rotation drive shaft; the T-core magnetic core is driven to rotate at a constant speed by a servo motor, and with the help of a tension-controllable wire feeding mechanism, the winding tension is kept constant and the coil layers are arranged tightly.

[0008] Preferably, the on-demand zoned powder supply execution unit includes a hollow spiral propulsion tube and a multi-point distributed nozzle array; the hollow spiral propulsion tube is driven by a stepper motor to adjust the powder output, and the multi-point distributed nozzle array is arranged circumferentially along the T-core magnetic core window area and connected to the powder storage bin through a flexible hose; when the coil is wound to a specified angle range, the synchronous and coordinated control center triggers the nozzles in the corresponding area to pulse-spray powder, achieving precise filling with spatial orientation and time synchronization.

[0009] Preferably, the synchronous collaborative control center has a built-in process database that stores the winding-filling matching parameter table corresponding to different specifications of T-core magnetic cores; the control logic calculates the required filling rate based on the current winding coil number n and the real-time rotation speed, and dynamically adjusts the rotation speed of the hollow spiral propeller tube and the nozzle opening sequence through a PID algorithm; a functional relationship model between winding progress and filling action is established, where k is an empirical coefficient used to prevent overfilling or underfilling.

[0010] Preferably, the integrated tooling system is equipped with a self-aligning positioning mechanism, which includes three sets of radially symmetrically arranged pressure-sensing pins. The ends of the pins contact the end face of the T-core magnetic core and output displacement signals to the central controller. When the clamping eccentricity error is detected to exceed 0.05mm, the central controller automatically drives the three-axis linkage actuator to fine-tune the position of the workpiece clamping and rotation drive unit until the coaxiality meets the standard, and then starts the winding program.

[0011] Preferably, the powder conveying path of the on-demand zoned powder supply execution unit is equipped with a fluidized bed device with a screen, the screen aperture being 50-80μm; an inert gas is introduced into the bottom of the fluidized bed device to agitate the airflow, keeping the magnetic powder in a loose and flowing state, preventing agglomeration and clogging of the hollow spiral propulsion tube, and ensuring the stability of powder supply under long-term continuous operation.

[0012] Preferably, the multi-point distributed nozzle array has a total of six nozzles, which are evenly distributed at 60° intervals along the circumference of the T-core window. Each nozzle is controlled by an independent solenoid valve and is sealed to a flexible hose. The synchronous collaborative control center determines whether to enter the preset powder filling section based on the angle signal of the current position of the winding head, and issues a pulse command to perform short-term spraying. The duration of a single spray is 0.2 to 0.5 seconds, and the spraying volume is coordinated and controlled by the rotation speed of the hollow spiral propulsion tube.

[0013] Preferably, the adjustable U-shaped clamp in the workpiece clamping and rotation drive unit adopts a quick-release interface design to adapt to T-core magnetic cores of different sizes; each clamp is equipped with an RFID tag to record its applicable model and geometric parameters; when the clamp is installed in place, the reader automatically identifies the tag information and uploads it to the central controller, and the system then retrieves the corresponding parameter table from the process database, including the winding speed curve, powder filling zoning logic and nozzle opening and closing sequence.

[0014] Preferably, the central controller receives feedback information from the position encoder and sensors, and dynamically adjusts the powder supply parameters to control the coefficient of variation of powder density between product batches within ±3%. The system forms a closed-loop collaborative mechanism of turning one turn and filling one section, realizing the transformation from independent step-by-step operation to integrated continuous manufacturing, significantly shortening the production cycle and improving product consistency.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention constructs an integrated chemical fitting system, using a workpiece clamping and rotation drive unit to fix the T-core magnetic core on the rotation axis and drive it to rotate at a uniform speed for coil winding. At the same time, with the help of an on-demand zoned powder supply execution unit integrated with the clamping unit, directional powder is injected into the winding gap according to preset logic during the winding process. The winding progress and speed data are acquired in real time by a synchronous collaborative control center, and the powder supply rate and discharge sequence are dynamically calculated and adjusted through a preset mathematical model, thereby forming a synchronous closed-loop control of winding and powder filling. This effectively avoids positioning deviations and connection delays caused by process separation and multiple clamping.

[0016] 2. This invention achieves deep synergy between winding and powder filling in the spatiotemporal dimensions, enabling the system to complete continuous manufacturing from magnetic core clamping, winding to powder filling without intermediate transfer, significantly improving production efficiency.

[0017] 3. This invention avoids the occurrence of local voids, bridging or overfilling through a precise synchronization control mechanism, which significantly improves the overall density and electromagnetic performance consistency of the magnetic core.

[0018] 4. This invention significantly improves the stability and reliability of mass production, meeting the manufacturing requirements of highly consistent and miniaturized T-core inductors. Attached Figure Description

[0019] Figure 1 is a schematic diagram of the integrated preparation process and integrated chemical equipment system for T-core wire winding and powder filling provided in this application.

[0020] Figure 2 is a schematic diagram of the workpiece clamping and rotation drive unit provided in this application.

[0021] Figure 3 is a schematic diagram of the on-demand zoned powder supply execution unit provided in this application.

[0022] Figure 4 is a schematic diagram of the self-centering positioning mechanism provided in this application.

[0023] Figure 5 is a schematic diagram of the structure of the fluidized bed device with screen provided in this application.

[0024] Figure 6 is a partial structural schematic diagram of the multi-point distributed nozzle array provided in this application.

[0025] Figure 7 is a schematic diagram of the adjustable U-shaped clamp with RFID tag provided in this application. Detailed Implementation

[0026] The present application will now be described in further detail with reference to embodiments. It is to be understood that the specific embodiments described herein are merely illustrative of the present application and are not intended to limit the scope of the application. Example

[0027] This embodiment provides a technical solution: an integrated preparation process and integrated chemical equipment system for T-core wire winding and powder filling, comprising the following steps: Step 1: Fix the T-core magnetic core to the rotation axis and drive it to rotate at a constant speed by means of workpiece clamping and rotation drive unit.

[0028] In this embodiment, the workpiece clamping and rotation drive unit serves as the execution base of the entire manufacturing system. Its main function is to achieve stable positioning and precise rotation drive of the T-core magnetic core. Specifically, this unit typically includes a high-precision pneumatic or electric chuck to concentrically clamp the core column portion of the T-core magnetic core, ensuring that its rotation axis coincides with the geometric center of the system, thereby guaranteeing the flatness of the winding arrangement. Simultaneously, this unit incorporates a servo motor and a precision reduction mechanism, enabling it to drive the T-core magnetic core to rotate at a preset speed, providing a stable motion reference for the continuous winding of the coil. This uniform rotation characteristic is a prerequisite for ensuring uniform subsequent winding spacing and precise powder filling timing.

[0029] Step 2: During the winding process, the on-demand zone powder supply execution unit injects powder into the winding gap according to preset logic.

[0030] In this embodiment, the on-demand zoned powder supply execution unit and the workpiece clamping and rotation drive unit are tightly integrated in physical space to form an integrated tooling structure, avoiding the flow of workpieces between different workstations in traditional processes. This unit includes multiple discharge ports arranged circumferentially along the magnetic core window and a power conveying mechanism. The power conveying mechanism can be a hollow spiral propulsion tube with an internal spiral rotor that directionally conveys insulating powder or colloidal powder from the powder storage tank along the pipe through rotation. The multiple discharge ports arranged circumferentially along the T-core magnetic core window ensure that powder is uniformly injected from different angles into the layers of the winding coil or the gaps between windings. This circumferential multi-point powder injection structure effectively solves the filling dead zone problem that may exist in single-point powder injection, achieving uniform powder coverage in three-dimensional space. In practical engineering applications, the cross-sectional shape of the discharge port can be designed as a flat slit or a circular aperture. The specific dimensions can be set according to the particle diameter and flow rate requirements of the powder, as long as stable and continuous powder output can be achieved.

[0031] Step 3: The winding progress and rotation speed data are acquired in real time through the synchronous collaborative control center, and the powder supply rate and discharge sequence are dynamically calculated and adjusted to form a synchronous closed-loop control of winding and powder filling.

[0032] In this embodiment, the synchronous collaborative control center acts as the brain of the system, responsible for coordinating the timing of mechanical motion and powder supply. It connects to the encoder of the workpiece clamping and rotation drive unit and the flow sensor of the on-demand zoned powder supply execution unit via a data bus, collecting real-time data on winding progress (e.g., number of turns wound) and rotational speed. A built-in process parameter database stores optimal filling parameters for different T-core core models and wire diameters, such as target filling density and powder filling coefficient. Based on this real-time data and preset parameters, the control algorithm dynamically calculates the current powder supply demand using a mathematical model. For example, the powder supply rate... With winding speed and target filling cross-sectional area The relationship between them can be represented as ,in This is a material property correction coefficient. Using this formula, the system can accurately calculate the required powder flow rate at any given moment and adjust the motor speed or valve opening of the power conveying mechanism accordingly, thereby regulating the powder supply rate in real time. Simultaneously, the system controls the opening and closing sequence of the discharge interface based on the winding progress, ensuring that powder is only ejected when passing through the powder injection area in a specific winding gap, forming a precise synchronous closed-loop control logic of winding one turn and filling one section.

[0033] Step 4: Enable the system to complete continuous integrated manufacturing from core clamping, wire winding to powder filling without intermediate transfer.

[0034] In this embodiment, the high degree of integration of the process flow is achieved through the collaborative work of the aforementioned units. Since the workpiece clamping and rotation drive unit and the on-demand zoned powder supply execution unit are integrated into the same workstation, the T-core magnetic core can complete the winding and powder filling processes sequentially after a single clamping, completely eliminating the auxiliary time required for intermediate unloading, transfer, and reclamping due to process separation in existing technologies. This continuous integrated manufacturing mode not only significantly improves production efficiency but, more importantly, avoids positioning errors caused by multiple clamping operations, ensuring the relative positional accuracy of the winding and the magnetic core, thereby improving the consistency of the electromagnetic performance of the final product.

[0035] Furthermore, the core innovation of this application lies in the construction of an integrated manufacturing system based on a synchronous mechanism for winding and powder filling. This system breaks through the limitations of the traditional manufacturing process where winding and powder filling are separated in sequence by deeply integrating the workpiece clamping and rotation drive unit with the on-demand zoned powder supply execution unit at the physical and control levels. The core lies in utilizing a synchronous collaborative control center to establish a real-time dynamic mapping relationship between winding motion parameters (rotation speed, progress) and powder supply parameters (rate, timing), achieving synchronous powder injection and coil winding at the microscopic level. This allows for gap filling without interrupting the winding process, achieving the technical concept of integrated continuous manufacturing.

[0036] Furthermore, the working process and principle of this application are as follows: After the system is started, the workpiece clamping and rotation drive unit first clamps the T-core magnetic core and drives it to rotate at a constant speed. The winding device, in coordination with this rotational motion, winds the enameled wire onto the magnetic core. Simultaneously, the synchronous control center monitors the current winding speed and the number of turns wound (winding progress) in real time. When the winding reaches the preset powder injection position, the control center calculates the target powder supply rate matching the current speed based on a built-in mathematical model and issues a control command to the on-demand zoned powder supply execution unit. The power conveying mechanism responds to this command, driving the powder through the pipeline to the discharge port at a specific speed or pressure. The discharge port opens under precise timing control, directionally spraying the powder into the winding gaps that are passing through the powder injection area. As winding continues, the system continuously repeats the above-mentioned monitoring-calculation-adjustment-execution cycle until the entire coil winding and filling work is completed. During this process, the powder supply rate is dynamically and adaptively adjusted according to the rotation speed fluctuations to ensure that the powder filling amount per unit length of winding remains constant, thereby achieving high-quality synchronous closed-loop control.

[0037] The T-core wire-winding and powder-filling integrated manufacturing process and integrated chemical assembly system in this embodiment effectively solve the problems of large clamping and positioning errors, low production efficiency, and low automation caused by process separation in existing technologies. This integrated system eliminates intermediate transfer links, significantly shortening the manufacturing cycle and increasing production capacity. Simultaneously, a closed-loop control algorithm based on real-time rotation speed and progress ensures a strict match between the powder supply rate and the winding speed, thereby achieving high uniformity and high density of powder filling. This avoids localized heating or electromagnetic performance degradation caused by uneven filling, greatly improving the product consistency and reliability of T-core magnetic components. It meets environmental testing requirements and exhibits good reliability and environmental adaptability.

[0038] Example 2: This embodiment provides a technical solution: a workpiece clamping and rotation driving unit, as shown in Figure 2, including the following steps: Step 1: An adjustable U-shaped clamp structure is adopted, with an elastic buffer layer on the inner wall of the clamp that fits and is fixed to the outer surface of the T-core magnetic core.

[0039] In this embodiment, the adjustable U-shaped clamp serves as the core positioning component of the workpiece clamping and rotation drive unit. Its U-shaped opening design can adapt to the outer contour of the T-core magnetic core. By adjusting the opening and closing distance of the clamp or replacing different sizes of clamping blocks, stable clamping of T-core magnetic cores of various sizes can be achieved. The elastic buffer layer on the inner wall of the clamp is usually made of high-molecular elastic materials such as silicone, rubber, or polyurethane. This elastic buffer layer provides sufficient clamping force to overcome rotational centrifugal force and winding tension, while using its own elastic deformation to absorb the microscopic unevenness of the clamping contact surface, increasing the effective contact area with the outer surface of the T-core magnetic core, thereby providing uniform and gentle clamping pressure. This close-fitting fixing method not only effectively prevents the T-core magnetic core from circumferential slippage or radial runout during high-speed rotation, ensuring the stability of the rotation axis, but also avoids damage to the magnetic core surface coating caused by rigid contact or magnetic core breakage caused by stress concentration, which is beneficial to protecting the product's appearance and structural integrity.

[0040] Step 2: One end of the fixture integrates a wire guide groove, and the other end is connected to a servo rotary drive shaft.

[0041] In this embodiment, a wire guide groove is integrated into the end of the adjustable U-shaped clamp to precisely guide the enameled wire during the initial winding stage. The groove width typically matches the wire diameter, ensuring the wire is accurately guided to the preset winding start position of the T-core magnetic core, preventing starting position deviations or first-turn tangling caused by free wire swing. Structurally, the wire guide groove can be integrally formed with the clamp body or mounted as a separate component on the clamp end face using fasteners. The other end of the adjustable U-shaped clamp is fixedly or via a transmission connection to a servo rotary drive shaft. The servo rotary drive shaft acts as a power transmission medium, transmitting the rotational torque of the servo motor to the adjustable U-shaped clamp, thereby driving the clamped T-core magnetic core to rotate around its axis. This connection method can be a key connection, a shrink sleeve connection, or a flange connection, etc., to ensure the reliability of torque transmission and facilitate coaxiality calibration.

[0042] Step 3: The T-core magnetic core is rotated at a constant speed by a servo motor, and a tension-controllable wire feeding mechanism is used to ensure that the winding tension is constant and the coil layers are tightly arranged.

[0043] In this embodiment, the servo motor, as a high-precision power source, possesses advantages such as fast response speed, high control accuracy, and wide speed range. It can precisely output rotational speed according to control commands, driving the T-core magnetic core to maintain a uniform rotational speed. Uniform rotation is fundamental to ensuring consistent coil turn spacing, avoiding uneven coil density caused by speed fluctuations. The cooperating wire feeding mechanism integrates tension feedback and control functions, typically including a tension sensor, tension wheel, wire feeding wheel, and tension adjustment actuator. During winding, the wire feeding mechanism monitors the tension changes of the conductor in real time and dynamically adjusts the wire feeding resistance or speed through a closed-loop control algorithm (such as Proportional-Integral-Derivative (PID) control) to counteract tension disturbances caused by changes in coil radius and friction fluctuations. The physical model of tension control can be represented as... ,in For the real-time tension of the conductor, The elastic coefficient of the tension system, This represents the change in displacement of the tension wheel. This represents the system's damping force. Using this model, the control system can maintain the conductor tension. The constant and appropriate tension ensures that the wires are tightly wound on the T-core magnetic core, and the coil layers are arranged tightly without gaps. This not only improves the stability of the winding duty cycle and inductance, but also effectively avoids electrical hazards such as coil loosening and short circuits caused by excessive tension thinning the wires or insufficient tension. As a result, the winding quality and electrical performance of the product are significantly improved.

[0044] The workpiece clamping and rotation drive unit in this embodiment ensures the stability of the T-core magnetic core clamping while effectively reducing the potential damage to the magnetic core caused by clamping stress, thus improving the flexibility and adaptability of the clamping. The servo motor and the tension-controlled wire feeding mechanism work together to create a constant speed and constant tension winding environment, ensuring the geometric accuracy and interlayer tightness of the coil arrangement. This solves the problems of low winding accuracy, loose structure, and unstable electrical performance caused by unstable clamping or tension fluctuations in traditional winding processes. It meets environmental testing requirements and has good reliability and environmental adaptability.

[0045] Example 3: This embodiment provides a technical solution: an on-demand zoned powder supply execution unit, as shown in Figure 3, including the following steps: Step 1: Set up a hollow spiral propulsion tube, driven by a stepper motor to adjust the powder output.

[0046] In this embodiment, the hollow spiral propulsion tube serves as the core power conveying component of the powder supply execution unit, and it contains spiral blades. Through precise angular displacement control of the stepper motor, the magnetic powder can be ejected from the storage bin at a constant volumetric flow rate. Unlike conventional pneumatic conveying or gravity feeding methods, this application innovatively employs a stepper motor-driven spiral propulsion method. This volumetric conveying principle establishes a strict linear mapping relationship between the powder output and the motor speed, a typical expression of which can be represented as follows: .in, The volumetric flow rate of the powder is given. This refers to the speed of the stepper motor. The flow coefficient is determined by the geometric parameters of the helical propeller tube. Based on this mathematical model, the control system can accurately calculate and adjust the speed of the stepper motor, thereby achieving micron-level precise control of the powder output. This design effectively avoids the problem of fluctuating powder supply caused by powder flowability fluctuations or unstable air pressure in traditional powder supply devices, ensuring a high degree of matching between the amount of powder injected into the winding gap per unit time and the winding rate.

[0047] Step 2: Set up a multi-point distributed nozzle array, arranged circumferentially along the T-core magnetic core window area and connected to the powder storage bin via a flexible hose.

[0048] In this embodiment, the multi-point distributed nozzle array overcomes the limitations of traditional single-nozzle center spraying. It consists of multiple independent or controllable nozzle units, forming a three-dimensional layout surrounding the magnetic core window. The flexible hose, serving as a flexible channel connecting the powder storage bin and the nozzle array, possesses excellent bending performance and wear resistance, adapting to the complex spatial routing requirements within the tooling system while reducing resistance and clogging risks during powder transport. This multi-point circumferential distribution design allows the nozzle spray direction to cover any angle region of the magnetic core window, providing a hardware foundation for achieving spatially directional filling.

[0049] Step 3: When the wire is wound to the specified angle range, the synchronous control center triggers the nozzles in the corresponding area to pulse-spray powder, achieving precise filling with spatial orientation and time synchronization.

[0050] In this embodiment, during operation, the synchronous control center monitors the rotation angle of the T-core magnetic core in real time. When the winding position enters the preset filling angle range, the system immediately sends a trigger signal to a specific nozzle in the multi-point distributed nozzle array located in that area. After receiving the signal, the nozzle performs a pulse-type spraying action, that is, it opens and closes rapidly in a very short time, accurately injecting powder into the gap formed by the current winding. This three-dimensional synchronous control mechanism of winding position-spatial angle-spraying sequence ensures that the powder filling action is strictly synchronized with the winding progress in time and precisely corresponds to the winding gap in space. Unlike the continuous overall spraying or post-vibration filling methods used in the prior art, the pulse-type partitioned spraying strategy of this application has unique advantages: it can achieve precise powder replenishment on demand and in position according to the non-uniformity of the winding distribution, effectively avoiding powder waste and distribution imbalance caused by non-winding areas or already filled areas, and also preventing bridging caused by excessive local powder accumulation, significantly improving the density and uniformity of powder filling.

[0051] In this embodiment, the on-demand zoned powder supply execution unit establishes a stable powder flow rate benchmark through the volumetric conveying characteristics of the hollow spiral propulsion tube; the multi-point distributed nozzle array utilizes its circumferential spatial distribution advantage to provide multi-dimensional spray coverage capability; and the synchronous collaborative control center serves as the logic core, converting the rotational motion of the winding into precise spatiotemporal trigger signals. These three components work together to form a closed-loop precision powder filling system. A stepper motor drives the hollow spiral propulsion tube, utilizing… This flow control model overcomes the bottleneck of unstable flow rate in traditional powder supply methods, achieving precise quantitative adjustment of powder output. Through the circumferential layout of a multi-point distributed nozzle array and pulse-jet control, this application innovatively constructs a refined operation mode of filling a section after each turn of the winding, solving the problem in traditional step-by-step processes where powder filling cannot follow the real-time changes in the winding's shape. This design not only greatly improves the local controllability and filling efficiency of the powder filling process but also significantly improves the uniformity of magnetic powder distribution in the winding gap, thereby effectively improving the magnetic circuit consistency and electromagnetic performance of the final product. It meets environmental testing requirements and exhibits good reliability and environmental adaptability.

[0052] Example 4: This embodiment provides a technical solution: a synchronous and collaborative control center, comprising the following steps: Step 1: Built-in process database, storing winding-filling matching parameter tables for different specifications of T-core magnetic cores.

[0053] In this embodiment, the process database serves as the core data center of the system, pre-loading standard process parameters for various T-core magnetic core models, such as core geometry, target number of winding turns, corresponding powder filling rate benchmark values, and the opening logic of nozzles in each zone. The aforementioned winding-powder filling matching parameter table is established based on extensive experimental data or simulation results, aiming to provide accurate process benchmarks for products of different specifications. Upon system startup, the synchronous collaborative control center can automatically retrieve and call the corresponding parameter table from the database based on the current T-core magnetic core model information, using it as the input benchmark and constraint conditions for subsequent real-time control algorithms.

[0054] Step 2: The control logic calculates the required powder filling rate based on the current number of windings n and the real-time rotation speed, and dynamically adjusts the rotation speed of the hollow spiral propeller tube and the nozzle opening sequence through a PID algorithm.

[0055] In this embodiment, unlike conventional open-loop control, a dynamic adjustment mechanism based on real-time state feedback is introduced. The control logic continuously monitors two key variables in the winding process: the number of winding turns *n* and the real-time rotational speed. The number of winding turns *n* reflects the axial cumulative progress of the winding, while the real-time rotational speed characterizes the linear velocity level of the winding. Based on these two variables, the system can calculate the required powder filling amount per unit time in real time, i.e., the required powder filling rate. To ensure that the actual powder supply rate closely follows the calculated target rate, the system uses a PID (Proportion-Integration-Differentiation) algorithm for closed-loop control of the actuator. The PID algorithm dynamically adjusts the speed of the drive motor of the hollow helical propulsion tube based on the deviation between the target powder filling rate and the actual powder supply rate, thereby precisely controlling the powder output flow rate of the helical propulsion tube. Simultaneously, the PID algorithm is also used to adjust the opening sequence and duration of each nozzle in the multi-point distributed nozzle array, ensuring that the powder injection time window is precisely synchronized with the time it takes for the winding to pass through a specific area. This PID-based multivariable collaborative control strategy can effectively overcome nonlinear interference factors such as mechanical transmission errors and powder flowability fluctuations, and achieve high-precision dynamic tracking of the powder supply process.

[0056] Step 3: Establish a functional relationship model between winding progress and powder filling action, where k is an empirical coefficient used to prevent overfilling or underfilling.

[0057] In this embodiment, the functional relationship model is the core mathematical model for achieving precise coordination between winding and powder filling in this application. Among them, Represents the current number of turns wound, used to characterize the axial position of the winding progress; This represents the real-time winding speed, i.e., the linear speed at which the wire is laid on the surface of the T-core magnetic core; This is an empirical coefficient, which is determined through experimental calibration based on the physical characteristics of different magnetic core specifications (such as window cross-sectional area, powder loose packing density, etc.) and target filling density. It is used to map the winding speed to the corresponding powder filling rate reference value. Then it means in the first The system should output a powder filling rate control command when the winding position is determined. Through this model, the system can establish a quantitative mapping relationship between changes in winding geometry and the intensity of powder filling action. In actual operation, as the number of winding coils increases... The increase and winding speed The function model can predict the powder filling demand in the next stage in real time, so that the control center can issue adjustment commands in advance, avoiding uneven powder filling caused by control lag.

[0058] Furthermore, in traditional step-by-step processes, due to the lack of real-time feedback on winding progress, the powder filling amount often relies on fixed parameter settings, which easily leads to overfilling (overflow or short-circuit risk) in sparsely wound areas or underfilling (voids or increased magnetic resistance) in densely wound areas. This application innovatively achieves adaptive matching between the powder filling rate and winding progress by combining the aforementioned mathematical model with a PID algorithm. When the winding speed is detected to be increasing or entering an interlayer region requiring more powder filling, the target powder filling rate calculated by the model increases accordingly, and the PID algorithm then drives the helical propeller to accelerate and extend the nozzle opening time; conversely, it decelerates or shortens the opening time. This precise control logic, allocated on demand, eliminates the hidden dangers of overfilling and underfilling at the source, ensuring the consistency and density of the magnetic powder filling inside the core, thereby significantly improving the electromagnetic performance stability and batch yield of the final product.

[0059] The synchronous collaborative control center in this embodiment solves the overfilling or underfilling problem caused by the mismatch between the powder filling rate and the winding progress in the prior art by setting up a built-in process database and matching parameter table, and establishing a functional relationship model based on the number of winding coils and the real-time rotation speed, combined with a PID algorithm for dynamic adjustment. By calculating the required powder filling rate in real time and dynamically adjusting the actuator, this application can achieve millisecond-level precise synchronization between the winding action and the powder filling action, avoiding powder waste and filling voids, effectively ensuring process consistency and repeatability, and significantly improving the manufacturing quality and production efficiency of T-core magnetic components. It can meet environmental testing requirements and has good reliability and environmental adaptability.

[0060] Example 5: This embodiment provides a technical solution: a self-aligning positioning mechanism, comprising the following steps: Step 1: The integrated chemical equipment system is equipped with a self-centering positioning mechanism, which includes three sets of radially symmetrically arranged pressure-sensing pins. The ends of the pins contact the end face of the T-core magnetic core and output displacement signals to the central controller.

[0061] In this embodiment, pressure-sensing ejector pins serve as precision feedback elements. Three sets of pins are arranged radially symmetrically to create a stable detection plane, enabling comprehensive capture of end-face runout and axial misalignment of the T-core magnetic core during clamping. The ejector pin ends maintain contact with the T-core's end face, and the contact pressure is converted into an analog or digital electrical signal, i.e., a displacement signal. This displacement signal reflects in real-time the degree and direction of the T-core's eccentricity relative to the ideal rotation center. The central controller receives this displacement signal and, based on the data differences from the three sets of ejector pins, calculates the current spatial position deviation of the T-core, including eccentricity distance and eccentricity angle, using a built-in spatial geometry algorithm.

[0062] Step 2: When the clamping eccentricity error exceeds 0.05mm, the central controller automatically drives the three-axis linkage actuator to fine-tune the position of the workpiece clamping and rotation drive unit until the coaxiality meets the standard, and then starts the winding program.

[0063] In this embodiment, the 0.05mm threshold is the upper limit of tolerance set according to the high-precision manufacturing requirements of T-core inductors. Exceeding this value means that the starting position of the winding is inaccurate, which can easily lead to uneven coil distribution and misalignment between the powder filling channel and the magnetic core window during subsequent winding. The three-axis linkage actuator, as the execution end, can perform micron-level translation or angular adjustment of the workpiece clamping and rotation drive unit in the X, Y, and Z degrees of freedom according to the instructions issued by the central controller, thereby driving the clamped T-core magnetic core to move synchronously. This closed-loop feedback adjustment mechanism can quickly respond to and correct the initial clamping error. The coaxiality meets the standard, which means that the coincidence of the rotation axis of the T-core magnetic core with the ideal processing axis of the system meets the preset accuracy requirements. At this time, the winding and powder filling processes have a unified geometric reference. Through a real-time displacement detection network constructed by three sets of pressure-sensing pins, the central controller can dynamically analyze the spatial attitude deviation of the T-core magnetic core and instruct the three-axis linkage actuator to perform multi-degree-of-freedom fine adjustments to the workpiece clamping and rotation drive unit until the three sets of displacement signals tend to be consistent, thereby eliminating clamping eccentricity at the physical level.

[0064] The self-centering positioning mechanism in this embodiment employs three sets of radially symmetrically arranged pressure-sensing pins for real-time displacement feedback. Combined with a closed-loop control system consisting of a central controller and a three-axis linkage actuator, it solves the problem of inaccurate initial positioning caused by manual clamping or fixed fixtures in existing technologies. This achieves the technical effects of eliminating clamping eccentricity errors, avoiding winding deviation and powder filling channel blockage, and significantly improving the automation reliability and product consistency of the integrated chemical equipment system. It meets environmental testing requirements and exhibits good reliability and environmental adaptability.

[0065] Example 6: This embodiment provides a technical solution: a fluidized bed device with a screen, comprising the following steps: Step 1: Install a fluidized bed device with a screen in the powder conveying path of the on-demand zoned powder supply execution unit. The screen aperture is [missing information]. .

[0066] In this embodiment, the fluidized bed device serves as a pre-treatment unit for powder conveying, primarily installed in the connecting pipeline between the powder storage silo and the hollow spiral propulsion tube. Its core function is to fluidize and filter impurities from the magnetic powder to be conveyed. The screen aperture is set to... The pore size range is designed to effectively intercept large particle agglomerates, sintered lumps, or external impurities that may be mixed in with the powder raw materials, preventing these abnormally sized particles from entering the downstream slender hollow spiral propulsion tube and causing mechanical jamming. At the same time, this pore size range ensures that fine powder meeting process requirements passes smoothly, balancing filtration accuracy and conveying throughput. It should be understood that the specific pore size value of the screen can be flexibly selected within the above range according to the actual particle size distribution characteristics of the magnetic powder; for example, it could be... or This application does not impose any special limitations on this aspect.

[0067] Step 2: Inert gas is introduced into the bottom of the fluidized bed device to disturb the airflow, keeping the magnetic powder in a loose and flowing state, preventing agglomeration and clogging of the hollow spiral propulsion tube, and ensuring the stability of powder supply during long-term continuous operation.

[0068] In this embodiment, a gas distribution plate is provided at the bottom of the fluidized bed device. Inert gas (such as nitrogen or argon) is pressurized by a gas pump and uniformly introduced into the device cavity from the bottom, passing through the powder accumulation layer from bottom to top. This upward airflow disturbance disrupts the natural packing and bridging structure between powder particles, overcomes the internal friction and adhesion between particles, and transforms the originally statically packed magnetic powder layer into a suspended state with fluid properties, i.e., a fluidized state. The use of inert gas can prevent the active magnetic powder from oxidizing or becoming damp during the airflow disturbance, ensuring the stability of the physicochemical properties of the powder material. By adjusting the flow rate and pressure of the inert gas, the degree of powder fluidization can be precisely controlled, keeping it in a suitable loose flow state and avoiding poor conveying due to insufficient fluidization or powder splashing and overflow due to excessive fluidization. During the powder conveying process, the loose powder processed by the fluidized bed device smoothly enters the hollow spiral propulsion tube under the action of gravity or pressure difference. Because the powder is already in a fluidized state and has been filtered through a screen, its frictional resistance during flow within the tube is significantly reduced, eliminating the risk of material arches or rat holes forming at the inlet of the feed tube due to powder moisture absorption, agglomeration, or bridging. This continuous and stable powder supply allows the system to adapt to long-term, high-load continuous operation, greatly reducing the frequency of downtime for cleaning and equipment maintenance costs caused by blockages, thereby ensuring the continuity and production efficiency of the T-core magnetic core winding and powder filling integrated manufacturing process.

[0069] The fluidized bed device with a screen in this embodiment effectively prevents powder agglomeration and clogging through screen filtration and inert gas fluidization, ensuring stable powder supply during long-term continuous operation. This guarantees the continuity and production efficiency of the integrated T-core winding and powder filling manufacturing process. It meets environmental testing requirements and has good reliability and environmental adaptability.

[0070] Example 7: This embodiment provides a technical solution: a multi-point distributed nozzle array, as shown in Figure 6, including the following steps: Step 1: A multi-point distributed nozzle array is set with a total of six nozzles, which are evenly distributed at 60° intervals along the circumference of the T-core window.

[0071] In this embodiment, the layout design ensures that the nozzles can achieve omnidirectional coverage within the window area of ​​the T-core magnetic core, eliminating filling dead zones. The uniform distribution of the six nozzles allows the powder to enter the winding gap simultaneously or sequentially from multiple directions, which is beneficial to improving the uniformity and density of the filling. In practical applications, the specific number of nozzles can also be adjusted according to the size specifications of the T-core magnetic core or the requirements of the winding process, such as four or eight, etc., and this embodiment does not impose any special limitation on this.

[0072] Step 2: Each nozzle is controlled by an independent solenoid valve and is sealed to a flexible hose.

[0073] In this embodiment, the independent solenoid valves enable precise, individual control of each nozzle, allowing the system to flexibly select specific locations or combinations of nozzles for operation without requiring all nozzles to operate simultaneously. The flexible hose connects the conveying channel to the nozzles; its flexibility allows for easy adaptation to the nozzle array's installation layout and mitigates vibration transmission during equipment operation, ensuring a tight and reliable connection. The sealed connection design effectively prevents powder leakage during conveying, guaranteeing a clean working environment and high material utilization.

[0074] Step 3: The synchronous and coordinated control center determines whether to enter the preset powder filling section based on the angle signal of the current position of the winding head, and issues a pulse command to perform short-term spraying.

[0075] In this embodiment, during the process, the synchronous collaborative control center monitors the rotation angle of the winding head in real time. When the winding head rotates to the preset angle range where powder needs to be filled (i.e., the powder filling section), the corresponding nozzle action is immediately triggered. The pulse command-based control method can precisely control the start and stop times of spraying, achieving precise tracking of spraying as soon as it arrives and stopping as soon as it passes, avoiding powder waste or contamination of non-target areas caused by continuous spraying. The specific range of the preset powder filling section can be flexibly set in the synchronous collaborative control center according to the winding process requirements, for example, setting the angle range corresponding to a specific gap between coil layers.

[0076] Step 4: The duration of a single injection is 0.2 to 0.5 seconds, and the injection volume is controlled in conjunction with the rotational speed of the hollow propeller tube.

[0077] In this embodiment, by limiting the duration of a single injection to between 0.2 and 0.5 seconds, the amount of powder injected each time can be controlled within a small and precise range, preventing damage to the winding structure or filler buildup due to excessive single injection volume. The amount of powder injected depends not only on the injection time but also on the rotational speed of the hollow helical propeller tube. The synchronous and coordinated control center can accurately calculate the powder output per unit time by coordinating the rotational speed of the hollow helical propeller tube and the opening duration of the solenoid valve, thereby achieving dual precise control over the total amount of powder injected. This coordinated control mechanism ensures a strict match between powder supply and winding progress, effectively avoiding insufficient or overfilling.

[0078] The multi-point nozzle array in this embodiment, through the uniform distribution of six nozzles and the on / off control of independent solenoid valves, combined with a pulse-type injection strategy based on angle signals, enables the powder to be accurately delivered to specific positions during the winding process. This on-demand, zoned, and precisely timed filling method not only improves the filling accuracy and consistency of magnetic powder in the winding gaps but also effectively reduces powder waste, optimizes the magnetic circuit performance of the T-core inductor, and enhances the overall product quality and production efficiency. It meets environmental testing requirements and exhibits good reliability and environmental adaptability.

[0079] Example 8: This embodiment provides a technical solution: an adjustable U-shaped clamp with an RFID tag, as shown in Figure 7, including the following steps: Step 1: The adjustable U-shaped clamp in the workpiece clamping and rotation drive unit adopts a quick-release interface design to adapt to T-core magnetic cores of different sizes.

[0080] In this embodiment, the quick-release interface aims to achieve rapid replacement and fastening of fixtures. Its specific structure can employ common mechanical connection methods such as snap-fit ​​connections, eccentric clamping, magnetic adsorption, or pneumatic quick-change. The actual implementation can be selected according to production line cycle time requirements and operating habits; this application does not impose any special limitations on this. Through the aforementioned quick-release interface design, operators can complete the disassembly and installation of fixtures of different specifications in a very short time without the need for complex tools, significantly reducing the labor intensity and time cost during changeover processes, thereby effectively improving the system's versatility and flexible manufacturing capabilities.

[0081] Step 2: Each fixture is equipped with an RFID tag to record its applicable model and geometric parameters.

[0082] In this embodiment, an RFID tag serves as the electronic identification of the fixture, fixedly installed on the non-working surface of the adjustable U-shaped fixture, such as the side of the fixture or near the mounting holes on the base, to avoid interference or damage during winding operations. The tag stores a unique identification code for the corresponding fixture and the geometric parameters of the compatible T-core magnetic core. These parameters include the outer diameter of the magnetic core, window height, winding width, and specific clamping and positioning reference data. This data forms the basis for the system to match subsequent process parameters, ensuring accurate information correlation between the physical fixture and the digital control system.

[0083] Step 3: Once the fixture is in place, the reader automatically identifies the tag information and uploads it to the central controller.

[0084] In this embodiment, the reader is typically integrated near the mounting base of the workpiece clamping and rotation drive unit. When the adjustable U-shaped fixture is installed in the predetermined position, the reader automatically scans and reads the data from the RFID tag via radio frequency signals. This identification process requires no manual intervention, effectively avoiding errors that may occur when manually entering parameters. The read tag information is sent to the central controller in real time. The central controller parses the received data to confirm the currently installed fixture model and its applicable magnetic core specifications.

[0085] Step 4: The system then retrieves the corresponding parameter table from the process database, including the winding speed curve, powder filling zone logic, and nozzle opening and closing sequence.

[0086] In this embodiment, the central controller retrieves and loads a process parameter table matching the identified fixture model from a pre-stored process database. This parameter table details the complete manufacturing process strategy for the current T-core magnetic core: the winding speed curve defines the optimal rotational speed at different winding stages or layers to balance winding efficiency and coil arrangement quality; the powder filling partitioning logic defines the rules for dividing the powder injection area for a specific magnetic core window structure; and the nozzle opening and closing sequence precisely controls the timing and duration of each nozzle in the multi-point distributed nozzle array. By automatically calling these parameters, the system can seamlessly switch to the optimal operating mode without manual resetting, thus achieving automation and intelligence in the model changeover process.

[0087] The adjustable U-shaped fixture with RFID tags in this embodiment, thanks to its quick-release interface design and RFID automatic identification technology, solves the problem of long changeover and debugging times and high error rates caused by manually resetting numerous process parameters after fixture replacement in traditional manufacturing processes. This significantly reduces changeover auxiliary time and improves production line flexibility and response speed. This design allows the system to flexibly adapt to the needs of small-batch, multi-variety mixed-line production, effectively improving equipment utilization and production organization flexibility. It meets environmental testing requirements and exhibits good reliability and environmental adaptability.

[0088] Example 9: This embodiment provides a technical solution: a continuous manufacturing mode based on closed-loop collaborative control, comprising the following steps: Step 1: The central controller, as the signal processing and decision-making center of the entire integrated chemical equipment system, eliminates random disturbances in the manufacturing process through real-time data acquisition and feedback adjustment.

[0089] In this embodiment, a position encoder is used to accurately detect the real-time rotation angle and winding progress of the T-core magnetic core, while a sensor is used to monitor physical quantities such as pressure, flow rate, and powder deposition status within the powder supply pipeline. The central controller receives feedback information from the position encoder and sensors and dynamically adjusts the powder supply parameters to control the coefficient of variation in powder density between product batches within ±3%. Specifically, based on the aforementioned feedback information, the central controller can identify abnormalities such as current winding speed fluctuations, changes in powder flowability, or powder supply delays, and accordingly issue immediate commands to adjust the rotational speed of the hollow spiral propeller tube or correct the nozzle opening timing. This dynamic adjustment mechanism ensures that the powder filling amount per unit length of coil remains highly constant, thereby strictly controlling the coefficient of variation in powder density between product batches within ±3%, significantly better than the density fluctuation level under traditional open-loop control methods, ensuring the consistency of the final product's electromagnetic performance.

[0090] Step 2: Based on this, the system forms a closed-loop collaborative mechanism of "one turn around and one section filled", realizing the transformation from independent step-by-step operation to integrated continuous manufacturing, significantly shortening the production cycle and improving product consistency.

[0091] In this embodiment, the closed-loop collaborative mechanism refers to the system triggering the corresponding powder filling action immediately upon completion of each coil turn or upon reaching a specific section, with the filling amount and position being corrected in real time based on the actual geometry of the current winding. By establishing a strict time-series mapping relationship between the winding action and the powder filling action, the powder filling process is no longer an independent process after winding, but rather a synchronous accompanying step in the winding process. This shift from independent step-by-step operations to integrated continuous manufacturing completely eliminates the transfer, waiting, and repeated clamping time of semi-finished products between different workstations in traditional processes, significantly reducing non-productive auxiliary time and thus significantly shortening the production cycle. Simultaneously, by reducing the accumulation of positioning errors caused by multiple clampings and compensating for process parameter drift through real-time feedback, the consistency of the product is comprehensively improved, meeting the stringent manufacturing precision requirements of high-density, miniaturized T-core inductors.

[0092] The continuous manufacturing mode based on closed-loop collaborative control in this embodiment compensates for process parameter drift through real-time feedback, thereby comprehensively improving product consistency and meeting the stringent manufacturing precision requirements of high-density, miniaturized T-core inductors. It also meets environmental testing requirements and exhibits good reliability and environmental adaptability.

[0093] The above description is merely a preferred embodiment of the present invention and is illustrative rather than restrictive. Those skilled in the art will understand that many changes, modifications, and even equivalents can be made within the spirit and scope defined by the claims of the present invention, all of which will fall within the protection scope of the present invention.

[0094] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

Claims

1. A T-core winding powder integrated preparation process and integrated tool system, characterized in that, include: The workpiece clamping and rotation drive unit (10) is configured to fix the T-core magnetic core (2) to the rotation axis and drive it to rotate at a constant speed for coil winding; The on-demand zoned powder supply execution unit (20) is integrated with the workpiece clamping and rotation drive unit (10) and includes multiple discharge interfaces (8) arranged circumferentially along the magnetic core window and a power conveying mechanism (7). It is configured to inject directional powder into the winding gap according to preset logic during the winding process. The synchronous collaborative control center (30) is connected to the workpiece clamping and rotation drive unit (10) and the on-demand zone powder supply execution unit (20), respectively. It has a built-in process parameter database and control algorithm, and is configured to acquire the winding progress and rotation speed data in real time. It dynamically calculates and adjusts the powder supply rate and discharge sequence of the on-demand zone powder supply execution unit (20) through a preset mathematical model, forming a synchronous closed-loop control of winding and powder filling. This enables the system to complete the continuous integrated manufacturing from core clamping, winding to powder filling without intermediate transfer.

2. The T-core winding and powder filling integrated preparation process and integrated tool system of claim 1, wherein The workpiece clamping and rotation drive unit (10) adopts an adjustable U-shaped clamp (3) structure. The inner wall of the clamp is provided with an elastic buffer layer and is fixed to the outer surface of the T-core magnetic core (2). One end of the clamp integrates a wire guide groove (4), and the other end is connected to a servo rotation drive shaft (5). The servo motor drives the T-core magnetic core (2) to rotate at a constant speed, and with the tension controllable wire feeding mechanism (6), the winding tension is kept constant and the coil layers are arranged tightly.

3. The T-core wire-wound powder-filling integrated preparation process and integrated chemical equipment system according to claim 1, characterized in that, The on-demand zoned powder supply execution unit (20) includes a hollow spiral propulsion tube (7) and a multi-point distributed nozzle array (8); the hollow spiral propulsion tube (7) is driven by a stepper motor to adjust the powder output, and the multi-point distributed nozzle array (8) is arranged circumferentially along the window area of ​​the T-core magnetic core (2) and connected to the powder storage bin (10) through a flexible hose (9); when the wire is wound to a specified angle range, the synchronous coordination control center (30) triggers the nozzles in the corresponding area to perform pulse-type powder spraying, so as to achieve precise filling with spatial orientation and time synchronization.

4. The T-core wire-wound powder-filling integrated preparation process and integrated chemical equipment system according to claim 1, characterized in that, The synchronous collaborative control center (30) has a built-in process database that stores the winding-filling matching parameter tables corresponding to different specifications of T-core magnetic cores (2); the control logic is based on the current winding coil number n and the real-time rotation speed. Calculate the required powder filling rate and dynamically adjust the rotation speed of the hollow spiral propeller tube (7) and the nozzle opening sequence using a PID algorithm; establish a functional relationship model between the winding progress and the powder filling action. , where k is an empirical coefficient used to prevent overfilling or omission.

5. The T-core wire-wound powder-filling integrated preparation process and integrated chemical equipment system according to claim 1, characterized in that, The integrated chemical fitting system is equipped with a self-aligning positioning mechanism, which includes three sets of radially symmetrically arranged pressure-sensing pins (13). The ends of the pins contact the end face of the T-core magnetic core (2) and output displacement signals to the central controller (12). When the clamping eccentricity error is detected to exceed 0.05mm, the central controller (12) automatically drives the three-axis linkage actuator (14) to fine-tune the position of the workpiece clamping and rotation drive unit (10) until the coaxiality meets the standard and then starts the winding program.

6. The T-core wire-wound powder-filling integrated preparation process and integrated chemical equipment system according to claim 1, characterized in that, The on-demand zoned powder supply execution unit (20) has a fluidized bed device (15) with a screen in its powder conveying path. The screen aperture is [missing information]. Inert gas is introduced into the bottom of the fluidized bed device to disturb the airflow, so that the magnetic powder remains in a loose and flowing state, preventing agglomeration and blockage of the hollow spiral propulsion tube (7), and ensuring the stability of powder supply under long-term continuous operation.

7. The integrated preparation process and integrated chemical equipment system for T-core wire winding and powder filling according to claim 3, characterized in that, The multi-point distributed nozzle array (8) has a total of six nozzles, which are evenly distributed at 60° intervals along the circumference of the T-core magnetic core (2) window. Each nozzle is controlled by an independent solenoid valve (16) and is sealed to the flexible hose (9). The synchronous collaborative control center (30) determines whether to enter the preset powder filling section based on the angle signal of the current position of the winding head, and issues a pulse command to perform short-term spraying. The duration of a single spray is 0.2 to 0.5 seconds, and the spraying volume is coordinated and controlled by the rotation speed of the hollow spiral propulsion tube (7).

8. The T-core wire-wound powder-filling integrated preparation process and integrated chemical equipment system according to claim 1, characterized in that, The adjustable U-shaped clamp (3) in the workpiece clamping and rotation drive unit (10) adopts a quick-release interface design to adapt to T-core magnetic cores (2) of different sizes; each clamp is equipped with an RFID tag (17) to record its applicable model and geometric parameters; when the clamp is installed in place, the reader automatically identifies the tag information and uploads it to the central controller (12), and the system then retrieves the corresponding parameter table from the process database, including the winding speed curve, powder filling partition logic and nozzle opening and closing sequence.

9. The integrated preparation process and integrated chemical equipment system for T-core wire winding and powder filling according to claim 1, characterized in that, The central controller (12) receives feedback information from the position encoder and sensors, and dynamically adjusts the powder supply parameters to control the coefficient of variation of powder density between product batches within ±3%. The system forms a closed-loop collaborative mechanism of one turn and one section of filling, realizing the transformation from independent step-by-step operation to integrated continuous manufacturing, significantly shortening the production cycle and improving product consistency.

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