Layered coil winding machine for transformer

Abstract

The utility model discloses a transformer layer type coil winding machine, which comprises a coil driving device, a winding displacement device and a paper supply device, the coil driving device is connected with a coil mould and drives the coil mould to rotate, and a lead and an insulation paper tape are wound on the coil mould through rotation winding. And the wire arranging device and the paper feeding device are respectively used for supplying a wire and an insulation paper tape to the coil driving device, and can move along the axial direction of the coil mold relative to the coil driving device, so that the wire and the insulation paper tape are wound on the coil mold along the axial direction of the coil mold. The winding machine provided by the utility model is high in automation degree, reduces the labor intensity of workers and the dependence on the experience of the workers, avoids the introduction of human errors, and effectively improves the quality of coil products.

Description

Technical Field

[0001] This utility model relates to the field of transformer manufacturing technology, specifically to a transformer layered coil winding machine. Background Technology

[0002] In the manufacturing process of transformers, the coil winding process is crucial. However, traditional coil winding methods are crude and involve many manual steps. Even when combined with equipment, the equipment suffers from low automation and low production efficiency, requiring continuous manual operation during the winding process. This not only results in high labor intensity and reliance on operator experience but also increases the probability of human error. Furthermore, the winding process is prone to defects such as unstable starting / braking, the need for manual arrangement, and uneven mechanical strength, leading to poor coil winding quality. Therefore, the transformer manufacturing industry urgently needs a more comprehensive and highly automated winding machine. Utility Model Content

[0003] The technical problem to be solved by this utility model is to address the above-mentioned shortcomings in the existing technology by providing a transformer layer coil winding machine. This winding machine has a high degree of automation, reduces the intensity of manual labor and dependence on personnel experience, avoids human error, and effectively improves the quality of coil products.

[0004] This utility model provides a transformer layer coil winding machine, including a coil driving device, a wire laying device, and a paper feeding device. The coil driving device is connected to the coil mold and drives the coil mold to rotate, so that the wire and insulating paper tape are wound on the coil mold by rotation and winding. The wire laying device and the paper feeding device are respectively used to supply the wire and insulating paper tape to the coil driving device, and can move relative to the coil driving device along the axial direction of the coil mold, so that the wire and insulating paper tape are wound on the coil mold along the axial direction of the coil mold.

[0005] Furthermore, the wiring device includes a reverse bending mechanism, which includes a guide wheel. The guide wheel is axially parallel to the coil mold and is located on one side of the coil mold in the wire entry direction. The guide wheel supports the wire that is wound around the coil mold so that the wire forms a bending arc opposite to the outer surface of the coil mold before being wound onto the coil mold.

[0006] Furthermore, the reverse bending mechanism also includes an adjustment component. The guide wheel is positioned above the coil mold and is spaced horizontally from the coil mold in a direction perpendicular to the axial direction. The wire winds from the side of the guide wheel away from the coil mold to the bottom of the guide wheel and then winds from the top of the coil mold to the side of the coil mold away from the guide wheel. The adjustment component is connected to the guide wheel and can drive the guide wheel to rise and fall, so as to move relative to the coil mold, thereby adjusting the degree of bending that the wire can achieve after being supported by the guide wheel.

[0007] Furthermore, the wiring device also includes a wiring frame mechanism and a wire mechanism. The wiring frame mechanism includes a support assembly and a mounting plate. The mounting plate is movably connected to the support assembly along the axial direction of the coil mold. The wire mechanism and the reverse bending mechanism are both mounted on the mounting plate and are supported by the mounting plate to move synchronously relative to the coil mold along the axial direction.

[0008] Furthermore, the conductor mechanism includes a guide wheel mounting plate and a wire feeding wheel. The guide wheel mounting plate is connected to the mounting plate. The axial direction of the wire feeding wheel is parallel to the axial direction of the coil mold and is rotatably connected to the guide wheel mounting plate. The reverse bending mechanism is connected to the guide wheel mounting plate. The conductor supplied by the wire feeding frame mechanism passes around the wire feeding wheel and is introduced into the reverse bending mechanism to finally reach the coil mold.

[0009] Furthermore, the paper feeding device includes an end insulation mechanism, which includes an end insulation box and a cylinder. The end insulation box is movably mounted on the mounting plate and located on the side of the conductor mechanism. The cylinder is connected to the end insulation box and is used to drive the end insulation box to move closer to and further away from the coil mold.

[0010] Furthermore, the paper feeding device includes an interlayer insulation mechanism, which includes a paper tape supply assembly. The paper tape supply assembly includes a housing, an unwinding shaft, and an unwinding drive. The unwinding drive is disposed inside the housing. The unwinding shaft is rotatably connected to the outer surface of the housing. The end of the unwinding shaft passes through the housing and is connected to the drive end of the unwinding drive. A paper tape reel made of insulating paper tape is connected to the unwinding shaft, which rotates under the drive of the unwinding drive and supplies insulating paper tape to the coil mold to form interlayer insulation on the coil mold.

[0011] Furthermore, the paper tape supply assembly also includes a tension adjusting component, which includes a rocker arm, a pneumatic float, and a guide wheel. The outer shell of the pneumatic float is hinged to the outer surface of the housing. The drive rod of the pneumatic float is connected to the end of the rocker arm. The end of the rocker arm connected to the drive rod is provided with a rotatable guide wheel, and the other end is hinged to the outer surface of the housing. The insulating paper tape is led out from the paper tape reel on the unwinding shaft, passes around the guide wheel, and is wound onto the coil mold to achieve automatic tensioning under the support of the pneumatic float.

[0012] Furthermore, the paper tape supply assembly also includes guide wheels, and multiple guide wheels are provided, all of which are rotatably connected to the outer surface of the housing. After the insulating paper tape is led out from the paper tape reel on the unwinding shaft, it passes around each guide wheel and is wound onto the coil mold.

[0013] Furthermore, the interlayer insulation mechanism also includes a chassis assembly and a transverse drive. The paper tape supply assembly is mounted on the chassis assembly, and the transverse drive is connected to the chassis assembly and drives the chassis assembly to move the paper tape supply assembly along the axial direction of the coil mold. The paper tape supply assembly is provided in two sets. The first set of paper tape supply assemblies is mounted on the chassis assembly, and the second set of paper tape supply assemblies is movably mounted on top of the first set of paper tape supply assemblies along the axial direction of the coil mold to adjust the overlap of the insulating paper tapes supplied by the two sets of paper tape supply assemblies in the width direction.

[0014] Furthermore, the coil driving device includes a spindle box and a tailstock box. Both the spindle box and the tailstock box are equipped with chucks. The spindle box and the tailstock box are respectively connected to both ends of the coil mold by the chucks. The spindle box is equipped with a spindle drive component, which is used to drive the chuck on the spindle box to rotate, thereby driving the coil mold to rotate and causing the chuck on the tailstock box to rotate accordingly.

[0015] Furthermore, the winding machine also includes an electrical control box and a base. The main spindle box and the tailstock box are movably mounted on the base along the axial direction of the coil mold so that they can move in opposite directions. The wire feeding device and the paper feeding device are both located on the same side of the connection between the main spindle box and the tailstock box, opposite to the interval between the main spindle box and the tailstock box used to install the coil mold, and are mounted on the base. The wire feeding device is positioned above the paper feeding device. The electrical control box is mounted on the base, located on the side of the main spindle box away from the tailstock box, and is used to control the operation of the main spindle box, the wire feeding device, and the paper feeding device and to supply power.

[0016] This utility model discloses a transformer layer coil winding machine that uses a wire feeding device and a paper feeding device to supply the wire and insulating paper tape respectively. During the winding process, the wire feeding device and the paper feeding device can also move axially relative to the coil mold. In addition, the coil driving device drives the coil mold to rotate and rewind, which can realize the winding of wire and insulating paper tape. The automation level of the entire winding process is greatly improved, and the degree of human intervention is reduced. Therefore, the reliance on human experience is reduced, avoiding the introduction of human error. As a result, the quality of coil products is also effectively improved. It is equivalent to providing a transformer layer coil winding equipment with more complete functions, higher degree of automation, and better output quality. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the transformer layer coil winding machine in this embodiment of the utility model;

[0018] Figure 2 This is a schematic diagram showing the guide wheel setting position of the transformer layer coil winding machine in this embodiment of the present invention;

[0019] Figure 3This is a schematic diagram of the reverse bending mechanism and the conductor mechanism of the transformer layer coil winding machine in this utility model embodiment;

[0020] Figure 4 This is a schematic diagram of the installation of the reverse bending mechanism of the transformer layer coil winding machine in this utility model embodiment;

[0021] Figure 5 This is a schematic diagram of the meshing of the rack and drive gear in the transformer layer coil winding machine according to an embodiment of this utility model;

[0022] Figure 6 This is a schematic diagram of the guide wheel connection structure of the transformer layer coil winding machine in this utility model embodiment;

[0023] Figure 7 This is a three-dimensional structural schematic diagram of the interlayer insulation mechanism of the transformer layer coil winding machine in this utility model embodiment;

[0024] Figure 8 This is another three-dimensional structural schematic diagram of the interlayer insulation mechanism of the transformer layer coil winding machine in this utility model embodiment;

[0025] Figure 9 This is a schematic diagram of the interlayer insulation mechanism of the transformer layer coil winding machine in this utility model embodiment;

[0026] Figure 10 This is a schematic diagram of the paper tape supply assembly located at the top in the transformer layer coil winding machine in this embodiment of the utility model;

[0027] Figure 11 This is another structural schematic diagram of the paper tape supply assembly located at the top in the transformer layer coil winding machine in this utility model embodiment;

[0028] Figure 12 This is a schematic diagram of the paper tape supply assembly located at the bottom in the transformer layer coil winding machine in this embodiment of the present invention;

[0029] Figure 13 This is another structural schematic diagram of the paper tape supply assembly located at the bottom in the transformer layer coil winding machine in this utility model embodiment;

[0030] Figure 14 This is a schematic diagram of the tension adjusting component in the transformer layer coil winding machine in this utility model embodiment;

[0031] Figure 15 This is a schematic diagram of the chassis assembly in the transformer layer coil winding machine according to an embodiment of this utility model;

[0032] Figure 16This is a schematic diagram showing the proximity switch arrangement of the chassis assembly in the transformer layer coil winding machine according to an embodiment of this utility model;

[0033] Figure 17 This is a schematic diagram showing the combination of the upper and lower paper tape supply components and the chassis component in the transformer layer coil winding machine of this utility model embodiment;

[0034] Figure 18 This is a schematic diagram of the main spindle box in the transformer layer coil winding machine of this utility model embodiment.

[0035] In the picture:

[0036] 1. Coil drive unit; 11. Spindle box; 12. Tailstock box; 13. Chuck; 14. Spindle drive unit;

[0037] 2. Cable laying device; 21. Reverse bending mechanism; 211. Guide wheel; 2111. Wire groove; 212. Adjustment component; 2121. Guide rail mounting plate; 2122. Lifting drive component; 2123. Linear guide rail slider; 2124. Rack; 2125. Drive gear; 2126. Limit block; 2127. Bearing seat; 213. Rotating shaft; 214. Threaded handle; 215. Compression spring; 22. Cable laying frame mechanism; 221. Support assembly; 2211. Cantilever beam; 2212. Cantilever beam support; 2213. Ball screw; 222. Mounting plate; 23. Wire laying mechanism; 231. Guide wheel mounting plate; 2311. First proximity switch; 2312. Zero position mounting plate; 232. Cable laying wheel; 24. Cable feeding frame mechanism;

[0038] 3. Paper feeding device; 31. End insulation mechanism; 311. End insulation box; 32. Interlayer insulation mechanism; 321. Paper tape supply assembly; 3211. Housing; 3212. Unwinding shaft; 3213. Unwinding drive; 3214. Guide wheel; 3215. Swing rod; 3216. Pneumatic float; 3217. Toothed pulley; 32171. Pulley baffle; 3218. Synchronous belt; 3219. Extension arm; 32191. Cylinder; 32192. Button; 322. Chassis assembly; 3221. Base plate; 3222. Chassis; 3223. Turbine screw jack; 3224. Guide rod; 3225. Oil drain assembly; 3226. Bellows cover; 3227. Second proximity switch; 323. Lateral movement drive; 33. Wide-width paper insulation mechanism;

[0039] 4. Coil mold; 5. Wire; 6. Insulating paper tape; 7. Electrical control box; 8. Base. Detailed Implementation

[0040] The technical solutions of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of this utility model.

[0041] In the description of this utility model, it should be noted that the terms "upper" and "lower" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience and simplification of the description and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0042] In the description of this utility model, the terms "first", "second", and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0043] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "connection," "setting," "installation," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0044] Example

[0045] like Figure 1 As shown, the transformer layer coil winding machine of this embodiment includes a coil driving device 1, a wire feeding device 2, and a paper feeding device 3. The coil driving device 1 is connected to the coil mold 4 and drives the coil mold 4 to rotate so that the wire 5 and the insulating paper tape 6 are wound on the coil mold 4 by rotation and winding. The wire feeding device 2 and the paper feeding device 3 are respectively used to supply the wire 5 and the insulating paper tape 6 to the coil driving device 1, and can move relative to the coil driving device 1 along the axial direction of the coil mold 4 so that the wire 5 and the insulating paper tape 6 are wound on the coil mold 4 along the axial direction of the coil mold 4.

[0046] The transformer layer coil winding machine of this embodiment uses a wire feeding device 2 and a paper feeding device 3 to supply the wire 5 and insulating paper tape 6 respectively. During the winding process, the wire feeding device 2 and the paper feeding device 3 can also move axially relative to the coil mold 4. In addition, the coil driving device 1 drives the coil mold 4 to rotate and rewind, which can realize the winding of the wire 5 and insulating paper tape 6. The automation level of the entire winding process is greatly improved, the degree of human intervention is reduced, and the dependence on human experience is reduced, avoiding the introduction of human error. As a result, the quality of the coil product is also effectively improved. It is equivalent to providing a transformer layer coil winding equipment with more complete functions, higher automation and better output quality.

[0047] In this embodiment, as Figures 2 to 4 As shown, the wiring device 2 includes a reverse bending mechanism 21, which includes a guide wheel 211. The guide wheel 211 is axially parallel to the coil mold 4 and is located on one side of the coil mold 4 in the wire inlet direction. The guide wheel 211 supports the wire 5 that is wound around the coil mold 4 so that the wire 5 forms a bending arc opposite to the outer surface of the coil mold 4 before being wound onto the coil mold 4.

[0048] In the past, after the coil was wound, it was usually pressed and shaped after demolding to ensure that the radial dimensions of the coil met the insulation requirements. However, in the traditional transformer layer coil winding process, once the tension of the winding is lost, the wire often rebounds, causing loosening before pressing. This is because the wire needs to release stress when wound on the curved surface of the coil mold, and there is currently no mature technology for stress release. This embodiment provides a reverse bending mechanism 21, which uses guide rollers 211 to support the wire 5 and pre-shape it with a bending arc opposite to the outer surface of the coil mold 4. This is equivalent to adding a reverse bending pretreatment process for the wire 5 in front of the coil mold 4. By applying reverse bending to the wire 5 before winding, plastic deformation is pre-set, and prestress is applied to the wire 5. Due to the presence of prestress, the wire 5 is less likely to return to its original shape after winding, and instead remains in a compliant state, which helps to achieve a more uniform stress distribution inside the wire 5 and reduce damage caused by stress concentration. Because this setup helps reduce rebound after winding, the conductor 5 is not only wound more tightly, but also controls the radial dimensions of the coil and improves the quality and performance of the coil, thereby enhancing the mechanical stability and safety of the coil product.

[0049] In this embodiment, the reverse bending mechanism 21 further includes an adjustment component 212. The guide wheel 211 is disposed above the coil mold 4 and is spaced from the coil mold 4 in a horizontal direction perpendicular to the axial direction. The wire 5 is wound from the side of the guide wheel 211 away from the coil mold 4 to the bottom of the guide wheel 211 and then from the top of the coil mold 4 to the side of the coil mold 4 away from the guide wheel 211. The adjustment component 212 is connected to the guide wheel 211 and can drive the guide wheel 211 to rise and fall, so as to move relative to the coil mold 4, thereby adjusting the degree of bending that the wire 5 can achieve after being supported by the guide wheel 211.

[0050] This layout in the embodiment is more reasonable, so that the wire 5 is wound around the coil mold 4 from the top downwards, and the side of the wire 5 that is wound around the coil mold 4 is located below the guide wheel 211, which fully exposes the coil mold and makes it easier for personnel to observe and operate the wires arranged on the coil mold 4.

[0051] When the curvature of the coil mold 4 varies, the fit between the conductor 5 and the coil is easily affected by the coil shape. Because the degree of bending of the conductor differs between the long and short axes, this can lead to uneven mechanical strength of the coil. The residual stress in the long axis section with a greater degree of bending is also relatively high. When the winding force is removed, the conductor will rebound more significantly to release the stress. In this embodiment, the adjustment component 212 is used to adjust the position of the guide wheel 211, thereby changing the degree of bending of the conductor 5. This means that the prestress applied to the conductor 5 through the guide wheel 211 is adjustable. Therefore, this embodiment can adapt to different curvature areas of the outer surface when used with structures such as oblong coil molds 4 and elliptical coil molds 4, achieving the beneficial effect of equal and balanced internal stress during conductor 5 winding, further optimizing the function of this device.

[0052] In this embodiment, the upper and lower limits of the lifting stroke of the guide wheel 211 are determined by the mechanical structure installation. The distance between the guide wheel 211 and the coil mold 4 in the horizontal direction perpendicular to the axial direction changes according to the different coil sizes, and is specifically selected according to the layout and production conditions.

[0053] In this embodiment, as Figure 3 and Figure 4As shown, the adjusting component 212 of the reverse bending mechanism 21 specifically includes a guide rail mounting plate 2121 and a lifting drive component 2122. The guide wheel 211 is rotatably mounted on the bottom end of the guide rail mounting plate 2121 using a bearing connection. The guide rail mounting plate 2121 is movably connected to the guide wheel mounting plate 231 of the guide wire mechanism 23 in the vertical direction. Specifically, a sliding pair such as a linear guide rail slider 2123 can be used to achieve a relative movable connection in the vertical direction (for example, a slider is set on the guide rail mounting plate 2121 and a sliding pair is set on the guide wheel mounting plate 231). The system consists of a guide rail (with the two components adapting to achieve sliding), a vertically arranged rack 2124 on the guide rail mounting plate 2121, a lifting drive component 2122 connected to the guide wheel mounting plate 231, and a drive gear 2125 at the drive end of the lifting drive component 2122. The drive gear 2125 meshes with the rack 2124, and the guide wheel 211 is rotatably connected to the guide rail mounting plate 2121. Under the drive of the lifting drive component 2122, the drive gear 2125 and the rack 2124 mesh and drive the wheel, causing it to rise and fall with the guide rail mounting plate 2121. The lifting drive component 2122 may include a servo motor and a reducer. The output shaft of the servo motor is connected to the input shaft of the reducer, and the input shaft of the reducer is connected to the drive gear 2125.

[0054] In this embodiment, as Figure 5 As shown, the guide rail mounting plate 2121 is also provided with limit blocks 2126. There are two limit blocks 2126, which are respectively set at both ends of the engagement stroke of the drive gear 2125 corresponding to the lifting stroke of the guide wheel 211. Therefore, when the guide wheel 211 is lifted to the end of its stroke, the drive gear 2125 and the rack 2124 also move relative to each other and reach the limit block 2126. This mechanical structure limits the movement to prevent the mechanism from malfunctioning and ensures operational safety.

[0055] The guide wheel mounting plate 231 can also be equipped with a first proximity switch 2311 and a zero-position mounting plate 2312. Specifically, a first proximity switch 2311 is provided on each of the upper and lower sides of the guide wheel mounting plate 231 at the position corresponding to the guide wheel mounting plate 2121, for sensing the position of the guide wheel 211 and serving as a sensor for the position of the guide wheel 211. An additional first proximity switch 2311 is provided below the guide wheel mounting plate 231 to serve as a zero-position sensing element for the guide wheel 211, so as to accurately locate and measure the upper and lower limits. Both of the two first proximity switches 2311 below are mounted on the zero-position mounting plate 2312.

[0056] In this embodiment, as Figure 6As shown, one end of the shaft 213 of the guide wheel 211 is connected to a bearing seat 2127 at the bottom of the guide rail mounting plate 2121 via a bearing, and the other end is connected to a threaded handle 214 via a threaded connection, so as to fix the guide wheel 211 by the threaded handle 214. A compression spring 215 can be provided between the threaded handle 214 and the inner hole of the shaft 213 to facilitate the installation and removal of the threaded handle 214. A wire groove 2111 can also be provided on the guide wheel 211 to fix the wire 5 and prevent the wire 5 from coming off.

[0057] In this embodiment, as Figure 1 As shown, the wiring device 2 also includes a wiring frame mechanism 22, a wire mechanism 23, and a wire feeding frame mechanism 24. The wiring frame mechanism 22 includes a support assembly 221 and a mounting plate 222. The mounting plate 222 is movably connected to the support assembly 221 along the axial direction of the coil mold 4. The wire mechanism 23 and the reverse bending mechanism 21 are both mounted on the mounting plate 222. The mounting plate 222 supports the wires and moves synchronously relative to the coil mold 4 along the axial direction, so that the wires 5 output by the wire mechanism 23 can be wound around the coil mold 4 along the axial direction of the coil mold 4. At the same time, the reverse bending mechanism 21 can move with the wire mechanism 23.

[0058] The wire feeding mechanism 24 moves synchronously with the mounting plate 222 to supply wire 5 to the wire feeding mechanism 23, so that the wire 5 is guided by the wire feeding mechanism 23, and then formed at the reverse bending mechanism 21 with a bending arc opposite to the outer surface of the coil mold 4 before being wound onto the coil mold 4.

[0059] The support assembly 221 includes a cantilever beam 2211 and a cantilever beam support 2212. The cantilever beam support 2212 is a rod, vertically installed on the mounting plane (base 8) of the transformer layer coil winding machine. The cantilever beam 2211 is a horizontal beam installed on top of the cantilever beam support 2212, arranged along the axial direction of the coil mold 4. The cantilever beam 2211 includes a support welded component. The support welded component on the cantilever beam 2211 is connected to the cantilever beam support 2212 by a hexagonal thin-thread nut (commonly known as a hexagonal fine-thread nut or fine-thread hexagonal nut). (The support welded component is a conventional part, and the connection method is a relatively conventional connection method, so it will not be described in detail here.)

[0060] A ball screw 2213 is installed on the cantilever beam 2211. The screw nuts at both ends of the ball screw are fixed to the cantilever beam 2211 so that the screw itself is arranged along the cantilever beam 2211. The screw mounting plate on the screw is connected to the mounting plate 222. A servo motor and a reducer can also be installed on the mounting plate 222. The servo motor is connected to the screw through the reducer, thereby driving the screw to rotate, so as to drive the mounting plate 222 to move along the screw, thereby realizing the movement of the guide wire mechanism 23 and the reverse bending mechanism 21. A linear guide or other sliding pair can also be provided between the mounting plate 222 and the cantilever beam 2211. In other embodiments, other conventional linear motion driving methods (such as rack and pinion meshing, telescopic drive, etc.) can also be used.

[0061] In this embodiment, the wire guide mechanism 23 includes a guide wheel mounting plate 231 and a wire guide wheel 232. The guide wheel mounting plate 231 is connected to the mounting plate 222. The axial direction of the wire guide wheel 232 is parallel to the axial direction of the coil mold 4 and is rotatably connected to the guide wheel mounting plate 231. The reverse bending mechanism 21 (with guide rail mounting plate 2121) is connected to the guide wheel mounting plate 231 (i.e., indirectly mounted on the mounting plate 222). The wire 5 supplied by the wire feeding frame mechanism 24 passes around the wire guide wheel 232 and is then introduced into the reverse bending mechanism 21 to finally reach the coil mold 4. The guide wheel mounting plate 231 can be a vertical plate surface perpendicular to the axial direction of the coil mold 4. There are two wire guide wheels 232, and the two arrangement positions are arranged in the front-back direction perpendicular to the axial direction of the coil mold 4, hence they can be called front and rear wire guide wheels, which together guide the winding of the wire 5.

[0062] In this embodiment, the winding machine can also use a wire feeding frame mechanism 24 to provide the wire 5 to the wire guide mechanism 23. The wire feeding frame keeps its coordinates synchronized when moving the wire laying mechanism, which can be achieved by using position detection combined with motor drive. The wire feeding frame mechanism 24 can be a conventional wire feeding machine or other equipment, which will not be described in detail here.

[0063] In this embodiment, the paper feeding device 3 includes an end insulation mechanism 31, which includes an end insulation box 311 and a cylinder. The end insulation box 311 (which can be a sliding pair or other movable connecting component arranged perpendicular to the coil mold 4) is movably mounted on the mounting plate 222, located on the side of the conductor mechanism 23, and is used to hold the end insulation paper. The cylinder is connected to the end insulation box 311 and is used to drive the end insulation box 311 to move closer to and further away from the coil mold 4. In this embodiment, there are two end insulation boxes 311, which are located on the left and right sides of the conductor mechanism 23 (along the axial direction of the coil mold). When the coil is wound to the end, the cylinder pushes the end insulation box 311 to extend the end insulation box 311 so that the operator can easily take the end insulation. When the end insulation is wound, the operator adds the end insulation paper tape at the corresponding end insulation position, and then the coil mold 4 can be rotated to rewind the end insulation.

[0064] In this embodiment, as Figures 7 to 9 As shown, the paper feeding device 3 also includes an interlayer insulation mechanism 32, which includes a paper tape supply assembly 321. The paper tape supply assembly 321 includes a housing 3211, an unwinding shaft 3212, and an unwinding drive 3213. The unwinding drive 3213 is disposed inside the housing 3211. The unwinding shaft 3212 is rotatably connected to the outer surface of the housing 3211. The end of the unwinding shaft 3212 passes through the housing 3211 and is connected to the drive end of the unwinding drive 3213. A paper tape reel wound with insulating paper tape 6 is connected to the unwinding shaft 3212, so that the unwinding drive 3213 drives the unwinding shaft to return to the coil mold 4 to supply insulating paper tape 6, so as to form interlayer insulation on the coil mold 4.

[0065] Specifically, such as Figures 10 to 13 As shown, the unwinding shaft 3212 is an air-expanding shaft, which is rotatably connected to the housing 3211 via bearings and bearing seats. The paper tape reel is clamped and fixed by air expansion (the structure and principle of the air-expanding shaft are conventional and will not be described in detail here). The unwinding drive 3213 is a servo motor. Both the output shaft of the servo motor and the unwinding shaft 3212 are connected to toothed pulleys 3217, which are blocked by pulley baffles 32171. The toothed pulleys 3217 on both are connected by a synchronous belt 3218 to achieve rotary transmission. That is, the servo motor drives the toothed pulley 3217 to drive another toothed pulley 3217 via the synchronous belt 3218. The other toothed pulley 3217 is connected via the air-expanding shaft (passing through the bearing seat, round nut, and baffle connecting plate, etc.), causing the insulating paper tape reel to rotate. In this embodiment, the internal transmission structures used for paper feeding in the two sets of paper tape supply assemblies 321 are identical.

[0066] In this embodiment, as Figure 14 As shown, the paper tape supply assembly 321 also includes a tension adjusting component, which includes a rocker arm 3215, a pneumatic float 3216, and a guide wheel 3214. The outer shell of the pneumatic float 3216 is hinged to the outer surface of the housing 3211. The drive rod of the pneumatic float 3216 is connected to the end of the rocker arm 3215. The end of the rocker arm 3215 connected to the drive rod is provided with a rotatable guide wheel 3214, and the other end is hinged to the outer surface of the housing 3211. The insulating paper tape 6 is led out from the paper tape reel on the unwinding shaft 3212, passes around the guide wheel 3214, and is wound onto the coil mold 4 to achieve automatic tensioning under the support of the pneumatic float 3216. For example, when the speed of the insulating paper tape 6 changes due to motor operation problems, the tension will change. The pneumatic float 3216 can drive the insulating paper tape 6 to support it through the air pressure of the internal gas, so that the insulating paper tape 6 will not become loose or too tight on the winding path. The specific air pressure of the pneumatic float 3216 can be set according to the actual working conditions, which varies depending on the paper tape material, environment, etc., and will not be elaborated here.

[0067] Traditional coil winding often involves winding and unwinding, driven by an asynchronous AC motor, resulting in unstable starting / braking and a lack of tension control system, thus leading to low coil winding quality. This embodiment, however, achieves automatic tensioning through a pneumatic float 3216, improving coil winding quality.

[0068] In this embodiment, the paper tape supply assembly 321 also includes guide wheels 3214. Multiple guide wheels 3214 are provided, each rotatably connected to the outer surface of the housing 3211. Specifically, one guide wheel 3214 is mounted on the swing arm 3215 of the tension adjustment component, while the remaining guide wheels 3214 are directly rotatably connected to the housing 3211. The insulating paper tape 6 is led out from the paper tape reel on the unwinding shaft 3212, passes around each guide wheel 3214, and is then wound onto the coil mold 4. The rotation shaft of the guide wheel 3214 can be connected using low-damping bearings and low-inertia rollers (i.e., selecting the structure with the lowest possible damping and low inertia among currently available bearings and rollers while meeting diameter and other requirements) to ensure smooth paper tape operation and reliable tension transmission. The arrangement and number of each guide wheel 3214 can be selected and adjusted according to the paper tape winding path and actual working requirements, which will not be elaborated here.

[0069] In this embodiment, as Figure 15 As shown, the interlayer insulation mechanism 32 also includes a chassis assembly 322 and a transverse drive 323. A paper tape supply assembly 321 is mounted on the chassis assembly 322. The transverse drive 323 connects to the chassis assembly 322 and drives the chassis assembly 322 to move the paper tape supply assembly 321 along the coil mold 4 axially. The wound coil includes a conductor layer, an insulation layer (i.e., interlayer insulation), and end insulation. Both ends of the conductor layer and the insulation layer have end insulation made of long strips of cardboard. The conductor layer and insulation layer are distributed alternately, with each insulation layer located between two conductor layers. The voltage difference between the two conductor layers gradually increases with the winding direction of the conductors, and the insulation layer is thicker where the voltage difference is greater. The general structure of the coil is basically the same as that of coils currently on the market, therefore, no drawings are provided for this embodiment.

[0070] In this embodiment, specifically, as follows: Figure 15As shown, the chassis assembly 322 includes a base plate 3221 and a chassis 3222. An interlayer insulation mechanism 32 is mounted on the chassis 3222. The chassis 3222 can move relative to the base plate 3221 along the axial direction of the coil mold 4. The base plate 3221 is movably connected to the base 8 in a direction perpendicular to the axial direction of the coil mold 4. The base plate 3221 and the chassis 3222, and the base plate 3221 and the base 8 are connected in the linear direction via sliding pairs (i.e., conventional sliders and slide rails). The driving motion in the moving direction is achieved by a servo motor driving a gear and a rack meshing with the gear. Each set of sliding pairs has at least one second proximity switch 3227 and one limit block at each end of the slide rail to limit the overall movement range of the mechanism. Figure 16 As shown, there are six second proximity switches 3227 at the chassis assembly 322. Assuming the movement direction between the base plate 3221 and the chassis 3222 is left-right, one second proximity switch 3227 is installed on the left end of the rear guide rail (the guide rail between the base plate 3221 and the chassis 3222), two second proximity switches 3227 are installed on the right end of the rear guide rail, two more second proximity switches 3227 are installed at the front and rear of the chassis assembly 322 (the guide rail between the base plate 3221 and the base 8), and the last second proximity switch 3227 is installed at the right end of the chassis assembly 322. Cables are routed between the relatively moving parts using cable carriers (a commercially available technology). All slide rail sections are equipped with bellows covers 3226 (a commercially available technology).

[0071] like Figure 17 As shown, the interlayer insulation mechanism 32 and the chassis 3222 can also move vertically, specifically through a screw jack 3223 for vertical drive. The screw jack 3223 is housed within the housing 3211 and passes through a hole in the lower base plate of the housing 3211, controlling the lifting and lowering of the interlayer insulation mechanism 32. The interlayer insulation mechanism 32 also has two sets (two rods per set, four in total) of guide rods 3224 that pass through the lower base plate to fix the chassis 3222, thus guiding the lifting and lowering. The base plate 3221 can be equipped with a five-position volumetric quantitative oil drain assembly 3225 to ensure a fixed amount of lubricating oil is provided to each moving part each time.

[0072] In this embodiment, two sets of paper tape supply components 321 are provided. The first set of paper tape supply components 321 is mounted on the chassis component 322, such as... Figure 12 and Figure 13 As shown, the second set of paper tape supply components 321 is movably mounted on top of the first set of paper tape supply components 321 along the axial direction of the coil mold 4, as... Figure 10 and Figure 11As shown, the overlap of the insulating paper tape 6 supplied by the two sets of paper tape supply assemblies 321 in the width direction is adjusted. Specifically, the housings 3211 of the two sets of paper tape supply assemblies 321 have two sets of linear guide rails and square sliders placed front and rear, forming a sliding pair to achieve a movable connection. The linear motion can be driven by rack and pinion gear meshing. For example, the bottom plate of the paper tape supply assembly 321 located at the top has a straight rack, which meshes with a drive gear. The drive gear is connected to a reducer and a servo motor to control the staggered movement of the upper and lower paper tape supply assemblies 321. The transmission structure of the insulating paper tape reel inside the two sets of paper tape supply assemblies 321 is the same (i.e., air shaft, toothed pulley, etc.).

[0073] In this embodiment, to ensure that the two layers of insulating paper tape are output from the two sets of paper tape supply assemblies 321 as close as possible, each set of paper tape supply assemblies 3211 has an extension arm 3219 on its housing 3211. The ends of the extension arms 3219 of the two sets of paper tape supply assemblies 3211 are adjacent vertically, and each end is equipped with a guide wheel 3214 for guiding the output insulating paper tape. The four paper tape guide wheels 3214 at the extension arms 3219 of the two sets of paper tape supply assemblies 3211 can be mounted at the extension arms 3219 using cylinders 32191. The four paper tape guide wheels 3214 are arranged in pairs, and the cylinders 32191 drive them to move closer and further apart to clamp the paper tape. Four buttons 32192 are provided to control the extension and retraction of the cylinders 32191 of each guide wheel 3214, thereby clamping and releasing the paper tape accordingly.

[0074] In this embodiment, in addition to the end insulation mechanism and the interlayer insulation mechanism, the paper feeding device 3 can also be equipped with a wide paper insulation mechanism 33. The wide paper insulation mechanism 33 can be installed on the base 8 and can be used to supply wide paper to the coil mold 4 and cut wide paper, etc. It can also be used to manually wind the wide paper of the coil mold 4. As an optional addition, it will not be described in detail in this embodiment.

[0075] In this embodiment, the coil drive device 1 includes a spindle box 11 and a tailstock box 12. Both the spindle box 11 and the tailstock box 12 are equipped with chucks 13. The spindle box 11 and the tailstock box 12 are respectively connected to both ends of the coil mold 4 via the chucks 13. The spindle box 11 contains a spindle drive component 14, which drives the chucks 13 on the spindle box 11 to rotate, thereby rotating the coil mold 4 and causing the chucks 13 on the tailstock box 12 to rotate accordingly. The chucks 13 on the tailstock box 12 are connected to the tailstock box 12 in a free-rotation manner, i.e., without a rotation drive, thus only performing clamping and following. Specifically, the chucks 13 adopt a four-jaw chuck structure. The spindle box 11 and tailstock box 12 can be connected to the base 8 via a sliding pair and a linear drive device to achieve axial movement along the coil mold 4. The coil loading, unloading, and flipping are done in a centrally symmetrical manner, that is, the spindle box 11 and tailstock box 12 move away from or closer to the coil mold 4 along the slide rail, thus providing a basic guarantee for the expansion and contraction of the spindle (clamping and fixing) and the 180° rotation of the coil (coil flipping).

[0076] like Figure 18 As shown, the spindle box 11 houses the spindle drive unit 14, and a lifting bolt is provided on the top for hoisting. The rotating spindle of the spindle box 11 passes through the box, with the outer end connected to the chuck 13 and the inner end connected to the spindle drive unit 14. Transmission can be achieved using pulleys, synchronous belts, etc. The specific drive method and connection structure are fairly conventional and will not be described in detail here. During coil winding, the tailstock box 12 has no active driving force and only moves as a follower.

[0077] In this embodiment, the winding machine also includes an electrical control box 7 and a base 8. The main spindle box 11 and the tailstock box 12 are axially mounted on the base 8 along the coil mold 4 so that they can move in opposite directions. The wire laying device 2 and the paper feeding device 3 are both located on the same side of the connection between the main spindle box 11 and the tailstock box 12, opposite to the position of the gap between the main spindle box 11 and the tailstock box 12 used to install the coil mold 4, and are mounted on the base 8. The wire laying device 2 is positioned above the paper feeding device 3. The electrical control box 7 is mounted on the base 8 and located on the side of the main spindle box 11 away from the tailstock box 12. It is used to control the operation of the main spindle box 11, the wire laying device 2 and the paper feeding device 3 and supply them with power. The wire feeding frame mechanism 24 is located on the side of the wire laying frame mechanism 22 away from the coil drive device 1 and moves synchronously with the wire laying frame mechanism 22.

[0078] In this layout, assuming the operator faces the winding machine, the operator faces the pay-off mechanism 24, and the conductor 5 is wound into the coil mold 4 in front of the operator. The operator can operate facing the winding machine. The spindle box 11 and electrical control box 7 are located on the left side, while the coil mold and main operating mechanisms (interlayer insulation mechanism 32 and conductor mechanism 23) are located directly in front of the operator. An auxiliary toolbox can be placed on the right side. The overall layout is U-shaped, facilitating manual operation. The main manual labor during winding is monitoring, requiring only appropriate add-on operations (such as winding end insulation).

[0079] More specifically, the wire feeding frame mechanism 24 is located on the side of the base 8 away from the coil mold 4 (this direction is set as the rear of the base 8), and the wire feeding frame mechanism 24 is parallel to the base 8. The main spindle box 11 and the tailstock box 12 are set on the front two sides of the base 8, the electrical control box 7 is set on the rear left side, the interlayer insulation mechanism 32 and the wide paper insulation mechanism 33 are set in the middle, and the wire feeding frame mechanism 22 is straddling above the two, which drives the conductor mechanism 23, the reverse bending mechanism 21 and the end insulation mechanism 31 to move.

[0080] In general, the transformer layer coil winding machine of this embodiment can be used in the fields of transformer manufacturing and coil winding technology. It is suitable for winding all layer coils, and is especially important for controlling coil size and saving materials when winding non-circular coils. The winding machine as a whole includes a winding machine base 8, a coil drive device 1 (including a spindle box 11 and a tailstock box 12), a paper feeding device 3 (including an end insulation mechanism 31, an interlayer insulation mechanism 32, and a wide-width paper insulation mechanism 33), a wire laying device 2 (including a wire laying frame mechanism 22, a reverse bending mechanism 21, a conductor mechanism 23, and a wire feeding frame mechanism 24), and an electrical control box 7. The spindle box 11, the tailstock box 12, the interlayer insulation mechanism 32, the wide-width paper insulation mechanism 33, the wire laying frame mechanism 22, and the conductor mechanism 23 are mounted on the winding machine base 8.

[0081] In this embodiment, when coil winding begins, the spindle drive 14 inside the spindle box 11 is activated, driving the coil mold to rotate via a transmission method such as pulleys. The tailstock box 12 is not powered during winding, and its end is also a retractable four-jaw chuck 13 that engages and fixes with the coil mold 4. The coil is fixed using the retractable four-jaw chuck 13, and the coil can be loaded and unloaded using a crane.

[0082] The interlayer insulation is made of strip paper tape. The paper tape forms trapezoidal insulation through motion synthesis (the rotational motion of the coil mold and the lateral movement of the interlayer insulation mechanism 32). The wire and paper are wound simultaneously, improving winding efficiency and reducing insulation material costs. Furthermore, a tension control system based on cylinder buffering is used during paper tape winding.

[0083] The addition of a follow-up reverse bending mechanism 21 during conductor winding applies prestress to the conductor to counteract the elastic recovery force generated by bending, thus balancing the internal pressure of the conductor on both the long and short axes of the non-circular coil. This makes the coil with the oblong structure more compact during winding and reduces rebound after winding. The degree of reverse bending of the conductor is adjustable. The conductor is pre-bent in the reverse direction, which adds additional radial force to the short axis of the non-circular coil after forward winding.

[0084] It is understood that the above embodiments are merely exemplary implementations used to illustrate the principles of this utility model, and the utility model is not limited thereto. For those skilled in the art, various modifications and improvements can be made without departing from the spirit and essence of this utility model, and these modifications and improvements are also considered to be within the protection scope of this utility model.

Claims

1. A transformer layer type coil winding machine, characterized in that: It includes a coil drive device (1), a wire laying device (2), and a paper feeding device (3). The coil drive device (1) is connected to the coil mold (4) and drives the coil mold (4) to rotate, so that the wire (5) and insulating paper tape (6) are wound around the coil mold (4) by rotation and winding. The wiring device (2) and the paper feeding device (3) are respectively used to supply wires (5) and insulating paper tape (6) to the coil driving device (1), and can move relative to the coil driving device (1) along the axial direction of the coil mold (4) so ​​that the wires (5) and insulating paper tape (6) are wound on the coil mold (4) along the axial direction of the coil mold (4). The cable routing device (2) includes a reverse bending mechanism (21), which includes a guide wheel (211). The guide wheel (211) is axially parallel to the coil mold (4) and is located on one side of the coil mold (4) in the wire entry direction. The guide wheel (211) supports the wire (5) that is wound around the coil mold (4) so ​​that the wire (5) forms a curved arc opposite to the outer surface of the coil mold (4) before being wound onto the coil mold (4); The reverse bending mechanism (21) also includes an adjustment component (212). The guide wheel (211) is positioned above the coil mold (4) and is spaced from the coil mold (4) in a horizontal direction perpendicular to the axial direction. The wire (5) winds from the side of the guide wheel (211) away from the coil mold (4) to the bottom of the guide wheel (211), and then winds from the top of the coil mold (4) back to the side of the coil mold (4) away from the guide wheel (211). The adjustment component (212) is connected to the guide wheel (211) and can drive the guide wheel (211) to rise and fall so as to move relative to the coil mold (4), thereby adjusting the degree of bending that the wire (5) can achieve after being supported by the guide wheel (211).

2. The transformer layer coil winding machine according to claim 1, characterized in that: The cable laying device (2) also includes a cable laying frame mechanism (22) and a wire mechanism (23). The cable tray mechanism (22) includes a bracket assembly (221) and a mounting plate (222), wherein the mounting plate (222) is movably connected to the bracket assembly (221) along the axial direction of the coil mold (4). The conductor mechanism (23) and the reverse bending mechanism (21) are both mounted on the mounting plate (222), and the mounting plate (222) supports the relative coil mold (4) to move axially synchronously.

3. The transformer layer coil winding machine according to claim 2, characterized in that: The wire guide mechanism (23) includes a guide wheel mounting plate (231) and a wire guide wheel (232). The guide wheel mounting plate (231) is connected to the mounting plate (222). The axial direction of the wire guide wheel (232) is parallel to the axial direction of the coil mold (4), and is rotatably connected to the guide wheel mounting plate (231). The reverse bending mechanism (21) is connected to the guide wheel mounting plate (231). The wire feeding device also includes a wire feeding frame mechanism (24), on which the wire (5) supplied by the wire feeding frame mechanism (24) passes around the wire feeding wheel (232) and is introduced into the reverse bending mechanism (21) and finally reaches the coil mold (4).

4. The transformer layer coil winding machine according to claim 2, characterized in that: The paper feeding device (3) includes an end insulation mechanism (31). The end insulation mechanism (31) includes an end insulation box (311) and a cylinder. The end insulation box (311) is movably mounted on the mounting plate (222) and located to the side of the conductor mechanism (23). The cylinder connection end insulation box (311) is used to drive the end insulation box (311) to move so as to be able to approach and move away from the coil mold (4).

5. The transformer layer coil winding machine according to claim 1, characterized in that: The paper feeding device (3) includes an interlayer insulation mechanism (32), which includes a paper tape supply assembly (321). The paper tape supply assembly (321) includes a housing (3211), an unwinding shaft (3212), and an unwinding drive (3213). The unwinding drive (3213) is disposed inside the housing (3211). The unwinding shaft (3212) is rotatably connected to the outer surface of the housing (3211), and the end of the unwinding shaft (3212) passes through the housing (3211) and is connected to the drive end of the unwinding drive (3213). A paper tape reel made of insulating paper tape (6) is connected to the unwinding shaft (3212), thereby rotating under the drive of the unwinding drive (3213) and supplying insulating paper tape (6) to the coil mold (4) to form interlayer insulation on the coil mold (4).

6. The transformer layer coil winding machine according to claim 5, characterized in that: The paper tape supply assembly (321) also includes a tension adjusting component, which includes a rocker arm (3215), a pneumatic float (3216), and a guide wheel (3214). The outer shell of the pneumatic float (3216) is hinged to the outer surface of the shell (3211), and the drive rod of the pneumatic float (3216) is connected to the end of the swing rod (3215). The swing arm (3215) has a rotatable guide wheel (3214) at one end connected to the drive rod, and the other end is hinged to the outer surface of the housing (3211). The insulating paper tape (6) is drawn out from the paper tape reel on the unwinding shaft (3212), passes around the guide wheel (3214), and is wound onto the coil mold (4) to achieve automatic tensioning under the support of the pneumatic float (3216).

7. The transformer layer coil winding machine according to claim 5, characterized in that: The paper tape supply assembly (321) also includes guide wheels (3214), of which multiple guide wheels (3214) are provided, each of which is rotatably connected to the outer surface of the housing (3211). The insulating paper tape (6) is drawn out from the paper tape reel on the unwinding shaft (3212), passes around each guide wheel (3214), and is then wound onto the coil mold (4).

8. The transformer layer coil winding machine according to any one of claims 5 to 7, characterized in that: The interlayer insulation mechanism (32) also includes a chassis assembly (322) and a lateral drive (323). The paper tape supply assembly (321) is mounted on the chassis assembly (322). The lateral drive (323) is connected to the chassis assembly (322) and drives the chassis assembly (322) to move the paper tape supply assembly (321) axially along the coil mold (4); The paper tape supply assembly (321) is provided in two sets. The first set of paper tape supply assemblies (321) is mounted on the chassis assembly (322). The second set of paper tape supply components (321) is movably mounted on top of the first set of paper tape supply components (321) along the axial direction of the coil mold (4) to adjust the overlap of the insulating paper tape (6) supplied by the two sets of paper tape supply components (321) in the width direction.

9. The transformer layer coil winding machine according to claim 1, characterized in that: The coil drive device (1) includes a spindle box (11) and a tailstock box (12), and both the spindle box (11) and the tailstock box (12) are equipped with chucks (13). The main spindle box (11) and the tailstock box (12) respectively clamp the two ends of the connecting coil mold (4) through the chuck (13). The spindle box (11) is equipped with a spindle drive (14) for driving the chuck (13) on the spindle box (11) to rotate, thereby driving the coil mold (4) to rotate, and causing the chuck (13) on the tailstock box (12) to rotate accordingly.

10. The transformer layer coil winding machine according to claim 9, characterized in that: It also includes an electrical control box (7) and a base (8). The main spindle box (11) and tailstock box (12) are axially mounted on the base (8) along the coil mold (4) so ​​that they can move towards or in opposite directions. The wiring device (2) and the paper feeding device (3) are both located on the same side of the line connecting the main spindle box (11) and the tailstock box (12), opposite to the position of the gap between the main spindle box (11) and the tailstock box (12) used to install the coil mold (4), and are mounted on the base (8), with the wiring device (2) straddling above the paper feeding device (3). The electrical control box (7) is mounted on the base (8) and located on the side of the spindle box (11) away from the tailstock box (12). It is used to control the operation of the spindle box (11), the wiring device (2) and the paper feeding device (3) and to supply them with power.

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