A winding tool for an ultra-long CS coil

Abstract

The utility model discloses a kind of winding tool of super-long CS coil, it is related to coil winding technical field, including winding machine and mould core, further including rotary support tool, rotary support tool is installed in the outside of mould core, mould core includes inner mould core and outer mould core, outer mould core is located in the outside of inner mould core, inner mould core and outer mould core are all provided with two, two outer mould cores are positioned by step cooperation, the inner wall of each outer mould core and the outer wall of each inner mould core are all through gradient cooperation.Mould core includes inner mould core and outer mould core, and cooperate the setting of end plate, long screw rod, so that mould core can withstand the huge pressure when super-long CS coil is wound, prevent tool deformation, guarantee winding precision.Set up mould core hoop, winding first layer hoop and winding second layer hoop, share part of the weight of coil, reduce the load that winding machine only clamps tool two ends bears.At the same time, avoid the additional resistance generated due to coil middle section deformation, make winding machine run more smoothly.

Description

Technical Field

[0001] This utility model relates to the field of coil winding technology, and in particular to a winding fixture for an ultra-long CS coil. Background Technology

[0002] The Ohm coil (CS coil for short) is 3.1 meters long and has an outer diameter of 0.45 meters (inner diameter of 0.33 meters). It is made of 28*18Ф10 oxygen-free copper (TU1) wire, with 150 turns per layer and two layers wound in both directions. During the winding process, a tensioning machine is used to pull the wire, and the high-tension winding makes it heavier and longer than conventional coils, with a length-to-diameter ratio of 6.9:1.

[0003] Currently, traditional winding fixtures have many shortcomings when dealing with the winding of such ultra-long CS coils. The mold core in traditional winding fixtures is a one-piece structure. While this can meet certain strength requirements when winding coils of conventional sizes, it is difficult for ultra-long CS coils, due to their length and weight, to withstand the enormous pressure and torque during winding. This leads to deformation and affects winding accuracy. For example, the mold core may bend and deform during winding, resulting in uneven distribution of the conductors and inconsistent turn counts across different parts of the coil, affecting coil performance. Furthermore, the demolding method for one-piece mold cores mainly relies on manual labor or simple mechanical assistance to forcibly remove the wound coil from the mold core. However, for ultra-long CS coils, due to the large contact area and strong friction between the coil and the mold core, this demolding method is not only inefficient but also highly likely to damage the coil. During demolding, uneven force may cause localized deformation of the coil or damage to the coil's insulation layer, reducing its insulation performance. Furthermore, traditional winding fixtures lack support structures for the middle section of the coil. Since winding machines typically only clamp the two ends of the winding fixture, and extra-long CS coils can reach approximately 3 meters in length, the middle section lacks effective support during winding and is prone to sagging or deformation under its own weight and winding tension. This deformation not only affects the coil's appearance but also leads to uneven tension distribution in the conductor during winding, thus affecting the tightness of the winding and the accuracy of the number of turns. Utility Model Content

[0004] The purpose of this invention is to provide a winding fixture for an extra-long CS coil to solve the above-mentioned technical problems.

[0005] The technical solution adopted in this utility model is as follows:

[0006] A winding fixture for an ultra-long CS coil includes a winding machine and a mold core disposed between two winding machines. It also includes a rotating support fixture installed on the outside of the mold core. The mold core includes an inner mold core and an outer mold core. The outer mold core is disposed on the outside of the inner mold core. There are two inner mold cores and two outer mold cores. The two outer mold cores are positioned and fitted together by a step. The inner wall of each outer mold core and the outer wall of each inner mold core are fitted together by an oblique angle.

[0007] Preferably, one end of one of the outer mold cores is provided with a positioning step, and the inner wall of one end of the other outer mold core is provided with a positioning groove, and the positioning step is inserted into the positioning groove.

[0008] Preferably, the inner wall of each outer mold core is provided with a first slope, and the outer wall of each inner mold core is provided with a second slope that matches the first slope.

[0009] Preferably, each of the outer mold cores includes at least three side plates, which are arranged in a ring to form the outer mold core.

[0010] Preferably, the device also includes end plates, with two end plates provided at both ends of the mold core. The two end plates are connected to the two inner mold cores by long screws. Each inner mold core has a connector at one end that cooperates with the winding machine, and the connector passes through the end plate.

[0011] Preferably, each of the outer mold cores has a Teflon coating on its outer wall.

[0012] Preferably, the rotary support fixture includes a core clamp, a first layer of clamps, and a second layer of clamps.

[0013] The core clamp, the first layer clamp, and the second layer clamp all include a base frame. A central frame is provided at the upper end of the base frame, and a support ring is provided rotatably in the middle of the central frame.

[0014] As a further preferred embodiment, the lower end of the central frame is provided with a base, and the upper end of the base frame is provided with a support rod, the base being connected to the support rod by a nut.

[0015] As a further preferred embodiment, the center frame is provided with a plurality of set screws, the set screws being threadedly engaged with the center frame, one end of the set screw being provided with a top seat, and a roller being rotatably provided inside the top seat, the roller contacting the outer wall of the support ring.

[0016] As a further preferred embodiment, the inner diameter of the support ring in the core clamp is smaller than the inner diameter of the support ring in the first layer of the clamp, and the inner diameter of the support ring in the first layer of the clamp is smaller than the inner diameter of the support ring in the second layer of the clamp.

[0017] The above technical solution has the following advantages or beneficial effects:

[0018] (1) In this utility model, the mold core includes an inner mold core and an outer mold core, and with the help of the end plate and long screw, the mold core can withstand the huge pressure when winding the ultra-long CS coil, prevent tooling deformation, and ensure winding accuracy.

[0019] (2) In this invention, a Teflon layer is provided on the surface of the mold core. Utilizing its low coefficient of friction, the friction between the coil and the mold core is significantly reduced. Simultaneously, the multi-layered structure of the mold core, especially the demolding method where the inner mold core is pulled out first, allows for easy demolding of the wound and cured coil. This effectively avoids damage to the coil caused by demolding difficulties, ensuring the integrity and quality of the coil, reducing the coil scrap rate due to demolding problems, and lowering production costs.

[0020] (3) In this utility model, the mold core clamp, the first layer clamp, and the second layer clamp are provided to share part of the weight of the coil and reduce the load borne by the winding machine only clamping the two ends of the tooling. At the same time, it avoids the additional resistance caused by the deformation of the middle section of the coil, making the winding machine run more smoothly. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the winding fixture for the extra-long CS coil in this utility model;

[0022] Figure 2 yes Figure 1 Enlarged view of point A in the middle;

[0023] Figure 3 This is a three-dimensional structural diagram of the mold core in this utility model;

[0024] Figure 4 This is a schematic diagram of the front structure of the mold core in this utility model;

[0025] Figure 5 yes Figure 4 Sectional view along the BB direction;

[0026] Figure 6 yes Figure 5 Enlarged view of point C in the middle.

[0027] In the diagram: 1. Mold core; 101. Inner mold core; 102. Outer mold core; 103. Positioning step; 104. Positioning groove; 105. Side plate; 106. End plate; 107. Long screw; 108. Connector; 2. Mold core clamp; 3. First layer clamp; 4. Second layer clamp; 5. Base frame; 6. Center frame; 7. Support ring; 8. Base; 9. Support rod; 10. Ejector screw; 11. Top seat; 12. Roller. Detailed Implementation

[0028] The technical solution 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. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0029] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this utility model and simplifying 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. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0030] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" 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 mechanical connection or an electrical 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 based on the specific circumstances.

[0031] Figure 1 This is a schematic diagram of the winding fixture for the extra-long CS coil in this utility model; Figure 2 yes Figure 1 Enlarged view of point A in the middle; Figure 3 This is a three-dimensional structural diagram of the mold core in this utility model; Figure 4 This is a schematic diagram of the front structure of the mold core in this utility model; Figure 5 yes Figure 4 Sectional view along the BB direction; Figure 6 yes Figure 5 A magnified view of point C. Please see below. Figures 1 to 6The diagram illustrates a preferred embodiment of a winding fixture for an extra-long CS coil. The fixture includes a winding machine and a mold core 1 positioned between two winding machines. It also includes a rotating support fixture mounted on the outside of the mold core 1. The mold core 1 comprises an inner mold core 101 and an outer mold core 102, with the outer mold core 102 located outside the inner mold core 101. Two inner mold cores and two outer mold cores 102 are provided. The two outer mold cores 102 are positioned and engaged by a step, and the inner wall of each outer mold core 102 is engaged with the outer wall of each inner mold core 101 by an oblique angle. In this embodiment, see [reference needed]. Figure 1 As shown, the two outer mold cores 102 are detachably connected, facilitating the disassembly of mold core 1 and the removal of the coil from it. The outer mold core 102 and inner mold core 101 employ a multi-part design, particularly the demolding method where the inner mold core 101 is pulled out first, allowing for easy demolding of the wound and cured coil. This effectively avoids damage to the coil caused by demolding difficulties, ensuring the integrity and quality of the coil, reducing the coil scrap rate due to demolding problems, and lowering production costs.

[0032] In this embodiment, the mold core 1 is divided into inner and outer sides, and the inner mold core 101 adopts a hollow design to reduce its weight. The inner mold core 101 and the outer mold core 102 are fitted with an angle, that is, the mounting surfaces of the inner mold core 101 and the outer mold core 102 are provided with a certain angle of draft angle to ensure the coaxiality accuracy of the two.

[0033] There are two outer mold cores 102, each with a length of approximately 1.5 meters. The two outer mold cores 102 are joined together by a step positioning mechanism to form a single piece of length.

[0034] Furthermore, as a preferred embodiment, one end of one outer mold core 102 is provided with a positioning step 103, and the inner wall of one end of the other outer mold core 102 is provided with a positioning groove 104, with the positioning step 103 inserted into the positioning groove 104. See details. Figure 6 As shown, the two outer mold cores 102 are joined together as a whole through the cooperation of the positioning step 103 and the positioning groove 104. The positioning step 103 is arranged in a ring shape.

[0035] Furthermore, as a preferred embodiment, the inner wall of each outer mold core 102 is provided with a first slope, and the outer wall of each inner mold core 101 is provided with a second slope that cooperates with the first slope. The cooperation of the first slope and the second slope facilitates the removal of the inner mold core 101 from the outer mold core 102.

[0036] Furthermore, as a preferred embodiment, each outer mold core 102 includes at least three side plates 105, which are arranged in a ring to form the outer mold core 102. During mold assembly, a 10mm gap is first created between two adjacent side plates 105 using spacers, and the mold core 1 is held in place by a rotating support fixture.

[0037] Furthermore, as a preferred embodiment, it also includes end plates 106. Two end plates 106 are provided at both ends of the mold core 1. The end plates 106 are connected to two inner mold cores 101 via long screws 107. Each inner mold core 101 has a connector 108 at one end that mates with the winding machine, and the connector 108 passes through the end plate 106. Two end plates 106 are provided. A groove is formed at the end of the end plate 106 near the mold core 1, and the end of the outer mold core 102 is inserted into the groove, facilitating the positioning of the outer mold core 102. The end plates 106, the outer mold core 102, and the inner mold cores 101 are locked and fixed together by long screws 107, ensuring the overall strength of the tooling. The long screws 107 are made of 45# steel, machined and quenched, with a screw grade of 8.8 or higher and a tensile strength test result of not less than 800MPa, ensuring the robustness of the tooling structure. Both ends of the long screws 107 are locked with nuts. The connector 108 is connected to an external winding machine, which drives the entire mold core 1 to rotate.

[0038] Furthermore, as a preferred embodiment, each outer mold core 102 has a Teflon coating on its outer wall. This arrangement facilitates demolding of the coil after winding and curing. During the winding process, as the winding progresses, the spacers are gradually removed, and the rotating support fixture is adjusted as needed. After the coil has cured and set, the long screw 107 and end plate 106 are removed first, then the inner mold core 101 is pulled out, and the entire mold core 1 can then be easily removed, completing the demolding operation. During assembly, the inner mold core 101 is first assembled between the two end plates 106, then the outer mold core 102 is assembled, and finally the end plates 106, outer mold core 102, and inner mold core 101 are locked and fixed by the long screw 107. The inner mold core 101 has a through hole along the axial direction for the long screw 107 to pass through.

[0039] Furthermore, as a preferred embodiment, the rotary support fixture includes a core 1 clamp, a first layer clamp 3, and a second layer clamp 4.

[0040] The mold core 1 clamp, the first layer clamp 3, and the second layer clamp 4 all include a base frame 5. A central frame 6 is vertically mounted on the upper end of the base frame 5, and a support ring 7 is rotatably mounted in the middle of the central frame 6. The base frame 5 is welded from carbon steel and uses a load-bearing, ground-mounted installation method to ensure the entire rotating support fixture is firmly fixed to the ground, providing a stable support foundation for subsequent components. The central frame 6 is height-adjustable to accommodate the height of the mold core 1. (See also...) Figure 1 As shown, the central frame 6 consists of two semi-ring structures, which are fixed together by bolts. The inner ring of the support ring 7 is designed to be assembled in two halves, which can be fixed together by bolts and together act as a clamp.

[0041] Furthermore, as a preferred embodiment, a base 8 is provided at the lower end of the central frame 6, and a support rod 9 is provided at the upper end of the base frame 5. The base 8 is connected to the support rod 9 by nuts. The base 8 is welded and fixed to the central frame 6, and the support rod 9 is threadedly engaged with the nuts. Several support rods 9 are provided, with threads on the upper and lower sides of the base 8, used to lock the base 8 onto the support rod 9. By rotating the corresponding nuts, the position of the base 8 on the support rod 9 can be adjusted, thereby adjusting the height of the base 8, and thus achieving the adjustment of the height of the central frame 6.

[0042] Furthermore, as a preferred embodiment, the central frame 6 is provided with several set screws 10, which are threadedly engaged with the central frame 6. One end of each set screw 10 is provided with a top seat 11, and a roller 12 is rotatably mounted inside the top seat 11, contacting the outer wall of the support ring 7. The set screw 10 has a rod-shaped structure with external threads on its surface, threadedly engaging with the central frame 6. The central frame 6 has threaded holes that engage with the set screw 10. The top seat 11 and the set screw 10 can be threadedly connected, which facilitates the adjustment of the angle of the roller 12, ensuring that the axis of the roller 12 remains parallel to the axis of the support ring 7. The top seat 11 has a U-shaped cross-section, and the roller 12 is mounted inside the top seat 11 via a rotating shaft and extends out of the top seat 11, then abuts against the outer wall of the support ring 7, thus facilitating the rotation of the support ring 7. Three set screws 10 are provided, arranged in a triangular pattern.

[0043] In other embodiments, a ball bearing can be provided at one end of the set screw 10, and the rotation of the support ring 7 can also be achieved by the ball bearing contacting the outer wall of the support ring 7.

[0044] Furthermore, as a preferred embodiment, the inner diameter of the support ring 7 in the core 1 clamp is smaller than the inner diameter of the support ring 7 in the first layer clamp 3, and the inner diameter of the support ring 7 in the first layer clamp 3 is smaller than the inner diameter of the support ring 7 in the second layer clamp 4. The inner diameters of the support rings 7 in the core 1 clamp, the first layer clamp 3, and the second layer clamp 4 increase sequentially. The support ring 7 of the core 1 clamp directly clamps the outer core 102, providing initial stable support. The inner diameters of the support rings 7 in the first layer clamp 3 and the second layer clamp 4 are larger than the outer diameter of the outer core 102, and do not contact the outer wall of the outer core 102. Instead, as the number of winding layers increases, they adapt to the outer diameters of the coils in the first and second layers, respectively, providing circumferential support to the middle section of the coil from all sides. The inner ring is connected to the ball bearing via a bolt, enabling easy rotation.

[0045] In this embodiment, before formally designing the length of the winding fixture mold core 1, a 10-turn coil winding experiment can be conducted. 18mm*28mm copper wire of the same specifications as the actual winding is selected, using the same insulation treatment and winding method, ensuring that the diameter of the test coil is no larger than the actual winding diameter. After winding and curing, the fixture is removed, allowing the test coil to rest fully. Subsequently, the dimensions of the 10 turns are accurately measured, and calculations show that the plastic deformation increase of a single turn of wire is 0.2mm. Therefore, it can be concluded that the total thickness increase of the CS coil after 150 turns is approximately 30mm. This experimental result provides a crucial basis for the subsequent design of the mold core 1 length.

[0046] In this embodiment, a 10-turn coil winding experiment is conducted before designing the length of the core 1 to accurately measure the increase in wire thickness due to plastic deformation, thereby compensating for this dimensional change during the design of the core 1. This effectively avoids inaccurate turns due to accumulated errors when winding a 150-turn coil, ensuring precise control of the coil turn count. Precise turn count is crucial for the CS coil to generate a stable and compliant magnetic field.

[0047] In this embodiment, the mold core 1 is made of 45# steel and is designed with a multi-layered structure. The inner mold core 101 is hollow to reduce weight while ensuring strength. The outer mold core 102 is spliced ​​and positioned using steps, and is secured by the precise positioning of the end plate 106 and the high-strength long screw 107. This design allows the fixture to withstand the enormous pressure during the winding of the ultra-long CS coil, preventing fixture deformation and ensuring winding accuracy. For example, during high-tension winding, the fixture will not twist or deform due to force, ensuring that the conductor can be wound evenly and tightly on the mold core 1, thus improving the quality stability of the coil.

[0048] In this embodiment, a Teflon coating is applied to the surface of the outer mold core 102. Utilizing its low coefficient of friction, this significantly reduces the friction between the coil and the mold core 1. Simultaneously, the multi-part structure design of the mold core 1, particularly the demolding method where the inner mold core 101 is pulled out first, allows for easy demolding of the wound and cured coil. This effectively avoids damage to the coil caused by demolding difficulties, ensuring the integrity and quality of the coil, reducing the coil scrap rate due to demolding problems, and lowering production costs.

[0049] In this embodiment, the core 1 clamp, the first layer clamp 3, and the second layer clamp 4 are divided into three stages, which can effectively support the middle section of the coil. From the core 1 clamp at the beginning of winding to the first layer clamp 3 and the second layer clamp 4 during the winding process, as the number of winding layers increases, it always matches the outer diameter of the coil, surrounding the coil from all sides to prevent deformation of the middle section of the coil under the winding force, thus ensuring the shape accuracy of the coil. For example, it avoids deformation such as local depressions or bulges in the middle section of the coil, ensuring the uniformity of the coil along its entire length, which is crucial for the coil to generate a uniform and stable magnetic field.

[0050] In this embodiment, the arrangement of the mold core 1 clamp, the first layer clamp 3, and the second layer clamp 4 distributes part of the coil's weight, reducing the load on the winding machine that is only clamping the two ends of the mold core 1. Simultaneously, it avoids additional resistance caused by deformation in the middle of the coil, making the winding machine run more smoothly. Furthermore, the stable winding process reduces the adjustment time required by the winding machine to address coil issues, improving winding efficiency. For example, in actual production, winding work that might otherwise take a long time can be completed with high quality in a shorter time using this fixture, improving production efficiency and meeting the needs of large-scale production.

[0051] In this embodiment, when actually winding the extra-long CS coil, the winding fixture is first assembled according to the above design, and then the wire is pulled by a tensioning machine to wind it under high tension. During the winding process, the length design of the mold core 1 is guided by the pre-wound experimental data to ensure the accuracy of the number of turns. At the same time, the structure of the mold core 1 ensures its own strength and stability during the winding process, and the rotating support fixture effectively prevents deformation in the middle section of the coil, reduces the burden on the winding machine, and improves winding efficiency. After winding, the Teflon plating and multi-part structure of the mold core 1 allow for easy demolding.

[0052] The above description is only a preferred embodiment of the present utility model and does not limit the implementation method and protection scope of the present utility model. Those skilled in the art should realize that all solutions obtained by equivalent substitutions and obvious changes made based on the description and illustrations of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A winding fixture for an extra-long CS coil, comprising a winding machine and a die core disposed between two said winding machines, characterized in that, It also includes a rotating support fixture, which is installed on the outside of the mold core. The mold core includes an inner mold core and an outer mold core. The outer mold core is located on the outside of the inner mold core. There are two inner mold cores and two outer mold cores. The two outer mold cores are positioned and fitted together by a step. The inner wall of each outer mold core is fitted with the outer wall of each inner mold core by an inclined plane.

2. The winding fixture for the extra-long CS coil as described in claim 1, characterized in that, One end of one of the outer mold cores is provided with a positioning step, and the inner wall of one end of the other outer mold core is provided with a positioning groove, and the positioning step is inserted into the positioning groove.

3. The winding fixture for the extra-long CS coil as described in claim 1, characterized in that, Each of the outer mold cores has a first slope on its inner wall, and each of the inner mold cores has a second slope on its outer wall that matches the first slope.

4. The winding fixture for the extra-long CS coil as described in claim 1, characterized in that, Each of the outer mold cores includes at least three side plates, which are arranged in a ring to form the outer mold core.

5. The winding fixture for the extra-long CS coil as described in claim 1, characterized in that, It also includes end plates, with two end plates provided at both ends of the mold core. The two end plates are connected to the two inner mold cores by long screws. Each inner mold core has a connector at one end that cooperates with the winding machine, and the connector passes through the end plate.

6. The winding fixture for the extra-long CS coil as described in claim 1, characterized in that, Each of the outer mold cores has a Teflon coating on its outer wall.

7. The winding fixture for the extra-long CS coil as described in claim 1, characterized in that, The rotary support fixture includes a core clamp, a first layer of clamps, and a second layer of clamps. The core clamp, the first layer clamp, and the second layer clamp all include a base frame. A central frame is provided at the upper end of the base frame, and a support ring is provided rotatably in the middle of the central frame.

8. The winding fixture for the extra-long CS coil as described in claim 7, characterized in that, The lower end of the central frame is provided with a base, and the upper end of the base frame is provided with a support rod. The base is connected to the support rod by a nut.

9. The winding fixture for the extra-long CS coil as described in claim 7, characterized in that, The central frame is provided with a plurality of set screws, which are threadedly engaged with the central frame. One end of each set screw is provided with a top seat, and a roller is rotatably provided inside the top seat. The roller contacts the outer wall of the support ring.

10. The winding fixture for the extra-long CS coil as described in claim 7, characterized in that, The inner diameter of the support ring in the core clamp is smaller than the inner diameter of the support ring in the first layer of the clamp, and the inner diameter of the support ring in the first layer of the clamp is smaller than the inner diameter of the support ring in the second layer of the clamp.

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