Tension-adjustable winding device

Abstract

The utility model discloses a tension-adjustable winding device. The tension-adjustable winding device comprises a working table, a guide rail, a sliding block and a display panel, a sliding block is arranged on a guide rail on the working table in a sliding manner; a tensioner is arranged on the sliding block; the tensioner comprises a base plate, a large third wheel, a seamless third wheel, a solid third wheel and an air cylinder. The large third wheel, the solid third wheel and the air cylinder are all installed on one side of the base plate, and a single-shaft magnetic powder brake used for controlling the tension of the large third wheel is arranged on the other side of the base plate, opposite to the large third wheel and coaxial with the large third wheel. The single-shaft magnetic powder brake is controlled by the adjusting knob to control the large third wheel, so that the winding tension of a copper wire wound on the large third wheel is adjusted, and the winding tension consistency of the transformer is ensured. The tension-adjustable winding device disclosed by the utility model has the advantages that the consistency of winding tension of a transformer can be ensured, the quality of products is improved, the reject ratio of the products is reduced, the working intensity of winding operators is reduced, the working efficiency of the operators is improved, and the like.

Description

Technical Field

[0001] The utility model relates to a winding auxiliary device, in particular to a tension-adjustable winding device. Background Art

[0002] During transformer production, the internal electromagnetic coils are wound individually. This process typically involves mounting a reel of electromagnetic wire on a horizontal winding machine, where the wire is manually tensioned. In existing technology, when transformer winding equipment in transformer production workshops lacks a tension payout function, winding tension must be manually controlled. This manual tension control relies entirely on the operator's feel, which is laborious and prone to fatigue.

[0003] In existing technology, most roller pay-offs only provide basic copper wire feeding functionality and lack control over the pay-off tension. Consequently, winding tension is controlled solely through employee experience. This manual winding tension control introduces significant quality risks to transformer production. Poor winding tension control during transformer production can have numerous consequences.

[0004] First, excessive winding tension can reduce the inter-turn gap between coils, reducing the inter-turn capacitance of the windings. This significantly increases leakage current, increases coil losses, and affects the inter-turn voltage distribution. This can lead to a decrease in the transformer's electrical performance, including reduced efficiency and increased temperature rise. It can also reduce the mechanical strength of the coils, causing local deformation and increased dielectric strength, ultimately leading to partial discharge and shortening the transformer's service life. Furthermore, for high-frequency transformers, excessive winding tension can cause the coils to shrink and become overly dense, resulting in insulated insulation that is too close together and prone to breakdown.

[0005] Secondly, too low a winding tension can cause the insulation layer between each coil to become too thick, increasing the coupling capacitance and inductance between the coils, which may affect the insulation performance of the transformer. Furthermore, in some winding systems, improper tension control can also cause the enameled wire to break and become misaligned, further reducing the coil's inter-turn withstand voltage and temperature parameters.

[0006] In short, during transformer manufacturing, outdated or unstable tension control technology can lead to sparse coil turns and poor coil quality. This not only affects transformer performance but also reduces production efficiency and product quality. Therefore, it is necessary to develop a tensioner that strictly controls winding tension, ensuring it remains within a predetermined range. This ensures winding quality and, in turn, improves transformer product quality and service life. Utility Model Content

[0007] The present invention aims to overcome the deficiencies in the above-mentioned prior art and to provide a tension-adjustable winding device so as to control the winding tension, reduce labor intensity and improve work efficiency.

[0008] The present invention adopts the following technical solutions to solve the technical problems.

[0009] The utility model provides a tension-adjustable winding device, comprising a work surface 1, a guide rail 2, a slider 3 and a display panel 4; the work surface is provided with a guide rail; a slider capable of linear motion along the length direction of the guide rail is slidably provided on the guide rail; a tensioner is provided on the slider; the tensioner comprises a base plate 5, a large wheel 6, a seamless wheel 7, a solid wheel 10 and a cylinder 8; the large wheel 6, the seamless wheel 7, the solid wheel 10 and the cylinder 8 are all installed on one side of the base plate; on the other side of the base plate, a single-axis magnetic powder brake 9 for controlling the tension of the large wheel is coaxially provided opposite to and opposite to the large wheel 6.

[0010] The structural features of the tension-adjustable winding device of the utility model are:

[0011] Furthermore, the base plate 5 includes a vertical plate 51 and a mounting plate 52 ; the mounting plate is fixed on the slider 3 .

[0012] Furthermore, the solid wheel 10 and the seamless wheel 7 are respectively provided above and below the side of the large wheel 6 away from the work surface 1 .

[0013] Furthermore, the seamless wheel 7 is connected to one end of the transmission rod 15 through the seamless wheel shaft 14; the other end of the transmission rod 15 is connected to the base plate 5 through the transmission rod shaft 151.

[0014] Furthermore, the lower end of the cylinder 8 is connected to the base plate 5 via a cylinder pin 16 ; the upper end of the cylinder 8 is connected to the transmission rod 15 via a cylinder connecting shaft 17 .

[0015] Furthermore, a cylinder joint 81 is provided at the upper end of the piston of the cylinder 8 .

[0016] Furthermore, the cylinder connecting shaft 17 is connected to the transmission rod 15 via a connecting pin 171 .

[0017] Furthermore, a first desktop wheel 18 is provided on the upper portion of the base plate 5 .

[0018] Furthermore, the first table top wheel 18 is arranged on the base plate 5 through a deep groove ball bearing 19 and a bearing mounting shaft 20 .

[0019] Furthermore, an extension plate 23 is fixedly provided on the base plate 5 , and a second tabletop wheel 22 is provided on the extension plate.

[0020] Compared with the existing technology, the beneficial effects of this utility model are embodied in:

[0021] The utility model discloses a tension-adjustable winding device, comprising a work surface, a guide rail, a slider, and a display panel. A slider is slidably mounted on the guide rail on the work surface; a tensioner is mounted on the slider; the tensioner comprises a base plate, a large pulley, a seamless pulley, a solid pulley, and a cylinder. The large pulley, the solid pulley, and the cylinder are all mounted on one side of the base plate. On the other side of the base plate, a single-axis magnetic powder brake is coaxially mounted opposite and opposite the large pulley to control the tension of the large pulley. The single-axis magnetic powder brake is controlled by adjusting a knob to control the large pulley, thereby adjusting the winding tension of the copper wire wound around the large pulley to ensure consistent transformer winding tension.

[0022] The utility model provides a tension-adjustable winding device, which has the advantages of ensuring the consistency of transformer winding tension, improving product quality, reducing product defect rate, reducing the workload of winding operators, and improving employee work efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a three-dimensional diagram of a tension-adjustable winding device of the present invention.

[0024] Figure 2 This is an exploded view of a tension-adjustable winding device of the present invention.

[0025] Figure 3 This is a front view of a tension-adjustable winding device of the present invention.

[0026] Figure 4 The utility model is a three-dimensional view of the connection part of the transmission rod and the connecting pin of the tension-adjustable winding device.

[0027] The present invention will be further described below through specific implementation methods in conjunction with the accompanying drawings. DETAILED DESCRIPTION

[0028] See also Figures 1 to 4The utility model is a tension-adjustable winding device, comprising a work surface 1, a guide rail 2, a slider 3 and a display panel 4; a guide rail is provided on the work surface; a slider capable of linear motion along the length direction of the guide rail is slidably provided on the guide rail; a tensioner is provided on the slider; the tensioner comprises a base plate 5, a large wheel 6, a seamless wheel 7, a solid wheel 10 and a cylinder 8; the large wheel 6, the seamless wheel 7, the solid wheel 10 and the cylinder 8 are all installed on one side of the base plate; on the other side of the base plate, a single-axis magnetic powder brake 9 for controlling the tension of the large wheel is coaxially provided opposite to and opposite to the large wheel 6.

[0029] like Figure 1 The utility model discloses a tension-adjustable winding device. A slider is provided on the guide rail of the work surface. A base plate is fixed to the slider, allowing the tensioner to move linearly along the guide rail along with the slider, thereby adjusting the working position as needed. During winding, the wire first passes over a large pulley and then around several other pulleys. The large pulley is controlled by an adjustment knob to control the single-axis magnetic powder brake, thereby adjusting the winding tension of the copper wire passing around the large pulley. This ensures the consistency of the transformer winding tension, improves product quality, and reduces the defective rate of products. It also reduces the workload of winding operators and improves employee work efficiency.

[0030] The large pulley is mounted on the central axis of the magnetic powder brake and can rotate with it. A magnetic powder brake is a highly efficient and versatile automatic control component that utilizes electromagnetic principles and magnetic powder to transmit torque. By filling the working gap between the stator and rotor with magnetic powder, the magnetic powder brake relies on the binding force between the magnetic powders generated by electromagnetic attraction and the friction between the magnetic powders and the working surface to transmit power and motion, and can precisely control and adjust torque. Key features of the magnetic powder brake include the linear relationship between the excitation current and torque, which makes torque control simple and precise. Torque can be easily controlled by simply adjusting the excitation current. Furthermore, under a stable excitation current, the transmitted torque is unaffected by the differential speed (slip speed) between the driving and driven parts, thus enabling stable transmission of constant torque. This brake device is suitable for various mechanical transmission systems requiring braking, speed regulation, tension control, and test loading.

[0031] In a specific implementation, the base plate 5 includes a vertical plate 51 and a mounting plate 52 ; the mounting plate is fixed on the slider 3 .

[0032] like Figures 2-3The vertical plate and mounting plate are an integrated structure. The mounting plate is an L-shaped plate that is fixed to the slider, allowing the entire base plate to move with the slider. The vertical plate is a flat plate for mounting components such as the large pulley, solid pulley 11, seamless pulley 7, tabletop pulley 12, and cylinder. These components, along with the mounting plate and single-axis magnetic powder brake, are located on either side of the vertical plate.

[0033] During specific implementation, the solid passing wheel 10 and the seamless passing wheel 7 are respectively provided above and below the side of the large passing wheel 6 away from the work surface 1 .

[0034] The solid pulley and the seamless pulley are arranged one above the other on one side of the large pulley. The outer circumference of the solid pulley is closely tangent to that of the large pulley. The seamless pulley is closely tangent to the outer circumference of the large pulley under the control of a pneumatic cylinder. The spacing between the seamless pulley and the large pulley can be adjusted by the cylinder. During the winding process, the cylinder causes the seamless pulley and the large pulley to clamp the copper wire. Then, according to the torque adjusted by the digital display panel, they rotate along with the large pulley to achieve the purpose of controlling the tension.

[0035] In a specific implementation, the seamless wheel 7 is connected to one end of the transmission rod 15 through the seamless wheel shaft 14 ; the other end of the transmission rod 15 is connected to the base plate 5 through the transmission rod shaft 151 .

[0036] like Figures 2-3 One end of the transmission rod is provided with a seamless wheel 7, and the other end of the transmission rod is connected to the base plate via a transmission rod shaft. The seamless wheel can rotate around the seamless wheel shaft, and the seamless wheel shaft is fixed in the shaft hole of the transmission rod. The other end of the transmission rod can rotate around the transmission rod shaft.

[0037] The large pulley 6 is flanked by a solid pulley 10 and a seamless pulley 7. The solid pulley 10 rotates via a deep groove ball bearing 19. The deep groove ball bearing 19 is mounted on a base plate 5 via a bearing mounting shaft 20. The seamless pulley 7 is connected to the transmission rod via a seamless pulley shaft 14.

[0038] In a specific implementation, the lower end of the cylinder 8 is connected to the base plate 5 via a cylinder pin 16 ; the upper end of the cylinder 8 is connected to the transmission rod 15 via a cylinder connecting shaft 17 .

[0039] During specific implementation, a cylinder joint 81 is provided at the upper end of the piston of the cylinder 8 .

[0040] like Figures 2-3 The cylinder joint 81 at the top of the piston is connected to the cylinder connecting shaft 17. The cylinder connecting shaft 17 is connected to the transmission rod 15 through a connecting pin 171.

[0041] In a specific implementation, the cylinder connecting shaft 17 is connected to the transmission rod 15 via a connecting pin 171 .

[0042] like Figures 2-3 The cylinder pin 4 is fixed to the base plate, and the lower end of the cylinder 8 is capable of rotating around the cylinder pin 4. A cylinder joint 81 is provided at the upper end of the cylinder 8. This joint is connected to the transmission rod 15 via a cylinder connecting shaft 17, allowing the cylinder to push the transmission rod 15 up and down to rotate around the transmission rod shaft 151, thereby adjusting the spacing between the seamless pulley and the large pulley. During operation, the cylinder's piston drives the cylinder joint 81 in linear motion, which in turn pushes the cylinder connecting shaft 17 up and down, further pushing the transmission rod 15 to rotate around the transmission rod shaft 151, which in turn drives the seamless pulley 7 at one end of the transmission rod 15 toward or away from the large pulley. In practice, the lower end of the cylinder 8 is hingedly connected to the cylinder pin 16, allowing the cylinder 8 to rotate around the cylinder pin 16. The cylinder connecting shaft 17 is hingedly connected to the connecting pin 171, allowing the cylinder connecting shaft 17, the cylinder joint, and the cylinder's piston to rotate around the connecting pin 171. At the same time, since there is a certain gap between the piston and the cylinder, the center line of the piston and the center line of the cylinder will be offset when the piston moves upward, and the piston rod itself has a certain elasticity. Moreover, the stroke of the piston in the utility model is very small, about 2 to 3 cm. Even if the movement trajectory of the connecting pin 171 following the rotation of the transmission rod is an arc, the problem of the piston rod bending will not occur.

[0043] like Figure 4 As shown, in another specific embodiment, the shaft hole of the transmission rod 15 that connects to the connecting pin 171 can also be set as a waist-shaped hole 152. The two ends of the waist-shaped hole 152 are semi-cylindrical surfaces 1521, and the middle part of the waist-shaped hole 152 is an arcuate surface 1522. That is, the waist-shaped hole is surrounded by two semi-cylindrical surfaces 1521 at the two ends and two arcuate surfaces 1522 at the two sides. In this way, the range of motion of the connecting pin 171 in the waist-shaped hole is larger, which is suitable for applications with large piston strokes.

[0044] In a specific implementation, a first desktop wheel 18 is provided on the upper portion of the base plate 5 .

[0045] The first desktop wheel 18 is located directly above the solid wheel 10. The center of the outer circumference of the first desktop wheel 18, the solid wheel 10 and the large wheel 6 are all provided with wire grooves for clamping copper wires in the wire grooves.

[0046] In a specific implementation, the first table top wheel 18 is arranged on the base plate 5 through a deep groove ball bearing 19 and a bearing mounting shaft 20 .

[0047] The deep groove ball bearing 19 is arranged on the base plate 5 through the bearing mounting shaft 20, and the first table top wheel is sleeved on the deep groove ball bearing, so that the first table top wheel can rotate freely.

[0048] In a specific implementation, an extension plate 23 is fixedly provided on the base plate 5 , and a second tabletop wheel 22 is provided on the extension plate.

[0049] The extension plate is bolted to the top of the base plate. The first tabletop guide pulley is mounted on the extension plate 23 via a deep groove ball bearing 19 and a bearing mounting shaft 20. A removable extension plate 23 is provided on the top of the base plate. When the winding method changes, the extension plate 18 is added to adjust the copper wire passing through the guide pulley to adapt.

[0050] The solid pulley 10, first tabletop pulley 18, and second tabletop pulley 22 have the same structure and are all mounted via deep groove ball bearings 19 and bearing mounting shafts 20. The solid pulley 10 and first tabletop pulley 18 are mounted one above the other on the base plate, while the second tabletop pulley 22 is mounted on an extension plate 23.

[0051] When winding, the copper wire first passes around the large wheel 6, and the winding torque is controlled by the single-axis magnetic powder brake 9 connected to the large wheel 6. Then it passes through the solid wheel 10 in contact with the large wheel (12) and then passes around the first desktop wheel 18.

[0052] The base plate is connected to the slider via bolts and can move along the guide rails in any linear direction. The torque of the single-axis magnetic powder brake 9 can be adjusted using a knob, and the display panel 4 is used to display the torque value.

[0053] The single-axis magnetic powder brake 9 is connected to the display panel 4 , and the display panel 4 displays the magnitude of the torque of the single-axis magnetic powder brake 9 , and the adjustment of the tension magnitude is reflected by the torque.

[0054] The utility model has an adjustable tension winding device, which can be equipped with a tension control system. The winding worker can adjust the current size through the knob, and control the magnetic powder's tension by changing the current size to control the suction force, thereby realizing visualization and automatic control of the winding tension. The utility model has an adjustable tension winding device, which can solve the problem of uncontrollable tension in the winding process, ensure the consistency of transformer winding tension, improve product quality, and reduce product defective rate; reduce the workload of winding operators, and improve employee work efficiency. By winding with the adjustable tension winding device of the utility model, the winding tension in transformer production becomes controllable, and the electrical performance, mechanical strength, insulation performance, production efficiency and product quality of the transformer can be improved.

[0055] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the present invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be encompassed within the present invention. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

[0056] In addition, it should be understood that although this specification is described in terms of implementation methods, not every implementation method contains only one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

Claims

1. A tension-adjustable winding device, characterized in that: The invention comprises a work surface (1), a guide rail (2), a slider (3) and a display panel (4); the work surface is provided with a guide rail; a slider capable of linear motion along the length direction of the guide rail is slidably provided on the guide rail; a tensioner is provided on the slider; the tensioner comprises a base plate (5), a large wheel (6), a seamless wheel (7), a solid wheel (10) and a cylinder (8); the large wheel (6), the seamless wheel (7), the solid wheel (10) and the cylinder (8) are all installed on one side of the base plate; on the other side of the base plate, a single-axis magnetic powder brake (9) for controlling the tension of the large wheel is provided opposite to and coaxial with the large wheel (6).

2. A tension-adjustable winding device according to claim 1, characterized in that: The base plate (5) comprises a vertical plate (51) and a mounting plate (52); the mounting plate is fixed on the slider (3).

3. The tension-adjustable winding device according to claim 1, wherein: The solid passing wheel (10) and the seamless passing wheel (7) are respectively provided above and below the side of the large passing wheel (6) away from the work surface (1).

4. The tension-adjustable winding device according to claim 1, wherein: The seamless wheel (7) is connected to one end of a transmission rod (15) via a seamless wheel shaft (14); the other end of the transmission rod (15) is connected to the base plate (5) via a transmission rod shaft (151).

5. The tension-adjustable winding device according to claim 4, characterized in that: The lower end of the cylinder (8) is connected to the base plate (5) via a cylinder pin (16); the upper end of the cylinder (8) is connected to the transmission rod (15) via a cylinder connecting shaft (17).

6. The tension-adjustable winding device according to claim 5, characterized in that: The upper end of the piston of the cylinder (8) is provided with a cylinder joint (81).

7. The tension-adjustable winding device according to claim 5, characterized in that: The cylinder connecting shaft (17) is connected to the transmission rod (15) via a connecting pin (171).

8. The tension-adjustable winding device according to claim 1, characterized in that: A first tabletop wheel (18) is provided on the upper portion of the base plate (5).

9. The tension-adjustable winding device according to claim 8, characterized in that: The first tabletop wheel (18) is arranged on the base plate (5) via a deep groove ball bearing (19) and a bearing mounting shaft (20).

10. The tension-adjustable winding device according to claim 1, characterized in that: An extension plate (23) is also fixedly provided on the base plate (5), and a second tabletop wheel (22) is provided on the extension plate.

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