A bidirectional winding machine

Abstract

The utility model discloses a kind of two-way winding machines, the two-way winding machine includes cutting unit, lower winding unit, upper winding unit and control system.Cutting unit integrated clamping mechanism and wire cutting mechanism, for fixed and cutting off wire rod;Lower winding unit and upper winding unit are respectively provided with liftable mandrel and shaft sleeve, synchronous reverse rotation is realized by servo motor drive, and shaft sleeve rear end is equipped with elastic member to provide axial pressure.Control system independently adjusts the speed difference of upper and lower winding unit, and closed-loop control lifting stroke.The winding method of two-way winding machine includes fixed wire rod, butt joint mandrel, synchronous reverse winding and automatic cutting etc. The utility model realizes the double-layer synchronous winding of flat wire, has the advantages of high production efficiency, high winding precision, high degree of automation, etc., and is suitable for high-standard manufacturing requirements of inductance coil and other magnetic components.

Description

Technical Field

[0001] This utility model relates to the technical field of magnetic coil winding equipment, and in particular to a bidirectional winding machine. Background Technology

[0002] With the rapid development of power electronics, new energy vehicles, and high-efficiency energy conversion equipment, the performance requirements for magnetic components such as inductors and transformers are increasing. Traditional winding processes mainly employ a single-axis winding method, where the wire is spirally wound in a single direction, suitable for processing round wires. However, for flat wires (such as copper flat wire and Litz wire), traditional winding methods have the following technical drawbacks:

[0003] Low winding efficiency: Single-axis winding machines can only wind layer by layer and cannot achieve synchronous winding between upper and lower layers, resulting in low production efficiency and difficulty in meeting the needs of large-scale production.

[0004] Uneven interlayer stress: During the winding process, flat wires are prone to loosening or deformation between layers due to uneven tension, which affects the electrical performance and mechanical stability of the product.

[0005] Insufficient winding precision: Traditional winding machines lack closed-loop control and cannot accurately adjust the speed difference between the upper and lower winding layers, resulting in inconsistent winding tightness, which affects the inductance and current carrying capacity of the final product.

[0006] Low level of automation: Existing equipment usually relies on manual intervention for wire positioning and cutting, which not only increases labor costs but also easily introduces quality fluctuations.

[0007] Currently, some improved winding equipment on the market have attempted to adopt a dual-axis winding scheme, but the following problems still exist:

[0008] The upper and lower winding spools are rigidly connected, which cannot adapt to tension adjustment for different wire diameters, and is prone to wire breakage or loose winding.

[0009] The lack of a precise wire positioning mechanism results in the initial end of the flat wire not being securely fixed, making it prone to deviation during winding.

[0010] The control system does not achieve dynamic adjustment of the speed difference, making it difficult to guarantee the synchronization and consistency of the upper and lower winding layers.

[0011] Therefore, in view of the shortcomings of the existing technology, it is necessary to design a bidirectional winding machine to solve the above problems.

[0012] It should be noted that the above introduction to the technical background is only for the purpose of providing a clear and complete explanation of the technical solution of this utility model and facilitating the understanding of those skilled in the art. It should not be assumed that the above content is known to those skilled in the art simply because it has been described in the background section of this utility model. Utility Model Content

[0013] To overcome the shortcomings of the prior art, the present invention discloses a bidirectional winding machine that can realize bidirectional synchronous winding of flat wires and has high-precision tension control, automatic cutting and intelligent adjustment functions to meet the high standard requirements of modern electronic component manufacturing.

[0014] This utility model discloses a bidirectional winding machine, comprising:

[0015] The cutting unit includes a front and rear telescopic mechanism. The output end of the front and rear telescopic mechanism is equipped with a clamping mechanism for clamping the wire and a cutting mechanism for cutting the wire. This unit integrates the traditionally separate clamping and cutting mechanisms, reducing space occupation, effectively preventing wire backing, and ensuring product winding accuracy.

[0016] The lower winding unit includes a lower frame, on which a first lifting drive and a first horizontal lifting plate driven by the first lifting drive are provided. A first mandrel and a first bushing sleeve sleeved on the outside of the first mandrel are rotatably connected to the first horizontal lifting plate. The first bushing sleeve is driven to rotate around its axis by the first drive. A first elastic element is provided between the rear end of the first bushing sleeve and the first horizontal lifting plate. The front end of the first bushing sleeve is connected to the lower winding spindle, and an openable flat wire positioning structure is provided on the side of the lower winding spindle.

[0017] The upper winding unit includes an upper frame, on which a second lifting drive and a second horizontal lifting plate driven by the second lifting drive are provided. The second horizontal lifting plate is provided with a second mandrel and a second bushing sleeve sleeved on the outside of the second mandrel. The second bushing sleeve is driven by the second drive to rotate around its axis. A second elastic element is provided between the rear end of the second bushing sleeve and the second horizontal lifting plate. The front end of the second mandrel extends to the outside of the second bushing sleeve and is coaxially aligned with the lower winding main shaft to receive the upper winding.

[0018] The lower and upper winding units provide stable axial pressure to the upper and lower layers of the coil during the winding process, preventing it from becoming loose.

[0019] The control system is used to independently adjust the speed difference between the first drive and the second drive, and to control the lifting stroke of the first lifting drive and the second lifting drive in a closed loop, so as to facilitate the control of processing parameters according to the coil model.

[0020] Preferred technical solution: The flat wire positioning structure includes a fixed flat wire baffle and a movable flat wire clamp, with a positioning groove between them for fixing the initial end of the flat wire.

[0021] Preferred technical solution: The first mandrel and first bushing of the lower winding unit are configured as two sets, and the two sets of first bushings are driven synchronously by a first drive in conjunction with a synchronous belt or gear set; the second mandrel and second bushing of the upper winding unit are configured as two sets, and the two sets of second bushings are driven synchronously by a second drive in conjunction with a synchronous belt or gear set.

[0022] Preferred technical solution: The first drive and the second drive are servo motors, and the first lifting drive and the second lifting drive are electric push rods.

[0023] Preferred technical solution: Bearings are connected to the outer periphery of both the first and second bushings to ensure the motion accuracy of the lower winding unit and the upper winding unit.

[0024] Preferred technical solution: An elastic reset component is provided between the flat wire clamp and the lower winding spindle to automatically release the flat wire after winding is completed.

[0025] Preferred technical solution: The docking end of the lower winding spindle and the second core shaft of the upper winding unit is provided with a magnetic adsorption structure to ensure the coaxial positioning of the upper and lower winding layers.

[0026] The winding method of this bidirectional winding machine includes the following steps:

[0027] S1. Pass the flat wire through the cutting unit, insert its front end into the positioning groove formed by the flat wire baffle and the flat wire clamp of the lower winding unit and fix it.

[0028] S2. The second spindle of the upper winding unit descends, and the first spindle of the lower winding unit rises, so that the front ends of the lower winding spindle and the second spindle are connected.

[0029] S3. Synchronously start the first drive and the second drive, control the lower winding spindle and the second core spindle to rotate in opposite directions at different speeds, so that the flat wire is spirally wound to form upper and lower coils. After docking, the speed of the two is adjusted by programming through an independent control system, so that the lower winding spindle and the second core spindle rotate synchronously at different speeds, thereby realizing the winding of the upper and lower layers of the inductor coil in opposite directions at different speeds.

[0030] S4. The clamping mechanism clamps the flat wire, and the cutting unit cuts the flat wire simultaneously.

[0031] Due to the application of the above technical solution, the beneficial effects of this utility model compared with the prior art are as follows:

[0032] 1) By synchronously reversing the winding of the upper and lower winding units, the flat wire can be wound in two layers at the same time, which significantly improves production efficiency and meets the needs of large-scale production.

[0033] 2) It adopts an independent servo motor drive and closed-loop control system, which can dynamically adjust the speed difference between the upper and lower winding shafts. This ensures consistent winding tightness even when there are differences in the number of winding coils in the upper and lower layers, thereby improving the electrical performance and mechanical stability of the product.

[0034] 3) It integrates automatic clamping, cutting and flexible reset functions, reducing manual intervention, lowering labor costs, and avoiding quality fluctuations caused by human operation.

[0035] 4) Both the rear ends of the first and second bushings are equipped with elastic elements. The upper and lower winding layers are squeezed inward by the elastic elements to ensure that the upper and lower coil layers are tightly attached, thereby improving the structural strength and performance of the product.

[0036] 5) Adjustable speed difference and tension control adapt to different wire diameters and winding requirements, avoiding wire breakage or loose winding problems. Attached Figure Description

[0037] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0038] Figure 1 This is a front view of a bidirectional winding machine according to the present invention;

[0039] Figure 2 This is an isometric side view of a bidirectional winding machine according to the present invention.

[0040] In the above figures, 1. Cutting unit; 11. Front and rear telescopic mechanism; 12. Clamping mechanism; 13. Wire cutting mechanism; 2. Lower winding unit; 21. Lower frame; 22. First lifting drive; 23. First horizontal lifting plate; 24. First spindle; 25. First bushing; 26. First drive; 27. Lower winding spindle; 28. Flat wire baffle; 29. ​​Flat wire clamp; 3. Upper winding unit; 31. Upper frame; 32. Second lifting drive; 33. Second horizontal lifting plate; 34. Second spindle; 35. Second bushing; 36. Second drive. Detailed Implementation

[0041] The following specific embodiments illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification.

[0042] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be used interchangeably where appropriate for the description of embodiments of this application herein. Furthermore, the terms "comprising" and "having," and their synonyms, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0043] In this application, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing the present invention and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0044] Furthermore, in addition to indicating direction or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this utility model according to the specific circumstances.

[0045] Furthermore, the terms "installation," "setting," "equipped with," "connection," "linking," "fitting," and "fitting" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or an internal connection between two devices, components, or parts. Similarly, "fitting" can mean completely or partially fitted. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0046] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0047] Example:

[0048] like Figure 1 and Figure 2As shown, this utility model discloses a bidirectional winding machine, including a cutting unit 1, a lower winding unit 2, an upper winding unit 3, and a control system. The main components of this utility model will be described in detail below:

[0049] Cutting Unit 1:

[0050] The cutting unit 1 is located at the front end of the equipment and includes a front-to-back telescopic mechanism 11, a clamping mechanism 12, and a wire-cutting mechanism 13. The front-to-back telescopic mechanism 11 uses an electric push rod to achieve linear movement, the clamping mechanism 12 uses a pneumatic clamp to fix the wire, and the wire-cutting mechanism 13 uses a high-precision blade to cut the wire. The integrated design of the cutting unit 1 reduces space occupation while ensuring that the wire does not retract during the cutting process.

[0051] Lower winding unit 2:

[0052] The lower winding unit 2 includes a lower frame 21, a first lifting drive 22, a first horizontal lifting plate 23, a first mandrel 24, a first bushing 25, and a lower winding spindle 27. The first lifting drive 22 is a servo electric push rod that drives the first horizontal lifting plate 23 to move vertically. The first mandrel 24 and the first bushing 25 are connected by bearings, and the first bushing 25 is driven to rotate by the first drive 26 of the servo motor. A spring is provided at the rear end of the first bushing 25 as the first elastic element to provide axial pressure to ensure tight winding. A flat wire positioning structure is provided on the side of the lower winding spindle 27, including a flat wire baffle 28 and a flat wire clamp 29, and the positioning groove formed by the two is used to fix the initial end of the flat wire.

[0053] Upper winding unit 3:

[0054] The upper winding unit 3 has a structure symmetrical to the lower winding unit 2, including an upper frame 31, a second lifting drive 32, a second horizontal lifting plate 33, a second mandrel 34, a second bushing 35, and a second drive 36. The front end of the second mandrel 34 extends to the outside of the second bushing 35 and is coaxially connected to the lower winding spindle 27. A spring is provided at the rear end of the second bushing 35 as a second elastic element to ensure the tightness of the upper winding.

[0055] Control system:

[0056] The control system uses PLC programming to independently adjust the speed difference between the servo motors of the upper and lower winding units, and achieves closed-loop control through encoder feedback. The parameters of the lifting drive and rotation drive can be adjusted in real time via a touch screen interface.

[0057] refer to Figure 1 and Figure 2 As shown, the usage method and principle of this utility model are described below:

[0058] Wire fixing: The flat wire is passed through the cutting unit 1 and the front end is inserted into the flat wire positioning groove of the lower winding unit 2. The flat wire positioning structure clamps the wire.

[0059] Mandrel docking: The second mandrel 34 of the upper winding unit 3 descends, and the first mandrel 24 of the lower winding unit 2 rises, so that the lower winding spindle 27 docks with the second mandrel 34. The docking end is equipped with a magnetic adsorption structure to ensure coaxial positioning.

[0060] Synchronous winding: The servo motors of the upper and lower winding units 2 are started. The lower winding spindle 27 rotates counterclockwise at speed N1, and the second spindle 34 rotates clockwise at speed N2. The control system dynamically adjusts the difference between N1 and N2 to ensure that the tension of the upper and lower winding layers is consistent.

[0061] Automatic cutting: After the winding is completed, the clamping mechanism 12 clamps the wire, the cutting mechanism 13 cuts the wire, and the flat wire clamp automatically releases the coil through the elastic reset component.

[0062] like Figure 1 and Figure 2 As shown, both the lower winding unit 2 and the upper winding unit 3 adopt a dual-axis design. Figure 2 As shown, the two sets of first bushings 25 of the lower winding unit 2 are connected by a synchronous belt and driven by the same servo motor; the two sets of second bushings 35 of the upper winding unit 3 are also connected by a synchronous belt and driven. This design can wind two coils simultaneously, doubling the production capacity.

[0063] like Figure 1 and Figure 2 As shown, bearings are connected to the outer periphery of both the first bushing 25 and the second bushing 35 to ensure that there is no vibration or offset during the winding process.

[0064] like Figure 1 and Figure 2 As shown, a flexible reset component is provided between the flat wire clamp 29 and the lower winding spindle 27 to automatically release the flat wire after winding is completed, avoiding manual intervention and realizing fully automated operation.

[0065] like Figure 1 and Figure 2 As shown, the lower winding spindle 27 and the second spindle 34 of the upper winding unit 3 are further provided with a magnetic adsorption structure to ensure the coaxial positioning of the upper and lower winding layers, which is suitable for long-term continuous production.

[0066] This embodiment details a specific implementation of a bidirectional winding machine. By optimizing the structural design, control logic, and key components, it achieves efficient and high-precision winding of flat wires. This equipment is suitable for the production of magnetic components such as inductors and transformers, and has broad market application prospects.

[0067] Finally, it should be noted that the above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A bi-directional winding machine characterized by, The utility model relates to a cutting unit (1) comprising a front and back telescopic mechanism (11), the output of front and back telescopic mechanism (11) is equipped with the clamping mechanism (12) for clamping wire and the wire cutting mechanism (13) for cutting wire; A lower winding unit (2) comprising a lower rack (21), the lower rack (21) is equipped with a first lifting drive (22) and a first horizontal lifting plate (23) driven by the first lifting drive (22), the first horizontal lifting plate (23) is rotatably connected with a first mandrel (24) and a first shaft sleeve (25) sleeved on the outside of the first mandrel (24), the first shaft sleeve (25) is driven to rotate around its axial direction by a first drive (26), a first elastic member is arranged between the rear end of the first shaft sleeve (25) and the first horizontal lifting plate (23); the front end of the first shaft sleeve (25) is connected with a lower wire winding main shaft (27), and the lower wire winding main shaft (27) is provided with an openable and closable flat wire positioning structure on the side; An upper winding unit (3) comprising an upper rack (31), the upper rack (31) is equipped with a second lifting drive (32) and a second horizontal lifting plate (33) driven by the second lifting drive (32), the second horizontal lifting plate (33) is provided with a second mandrel (34) and a second shaft sleeve (35) sleeved on the outside of the second mandrel (34), the second shaft sleeve (35) is driven to rotate around its axial direction by a second drive (36), a second elastic member is arranged between the rear end of the second shaft sleeve (35) and the second horizontal lifting plate (33); the front end of the second mandrel (34) extends to the outside of the second shaft sleeve (35) and is coaxially arranged with the lower wire winding main shaft (27); A control system for independently adjusting the speed difference of the first drive (26) and the second drive (36) and closed-loop controlling the lifting stroke of the first lifting drive (22) and the second lifting drive (32). The flat wire positioning structure comprises a fixed flat wire baffle (28) and a movable flat wire clamping plate (29), and a positioning groove for fixing the initial end of the flat wire is formed between the two.

2. A bidirectional winding machine according to claim 1, characterized in that: The first mandrel (24) and the first shaft sleeve (25) of the lower winding unit (2) are provided in two groups, the first shaft sleeves (25) of the two groups are synchronously driven by the first drive (26) through a synchronous belt or a gear set; the second mandrel (34) and the second shaft sleeve (35) of the upper winding unit (3) are provided in two groups, the second shaft sleeves (35) of the two groups are synchronously driven by the second drive (36) through a synchronous belt or a gear set.

3. A dual direction winding machine as claimed in claim 1, wherein: The first drive (26) and the second drive (36) are servo motors, and the first lifting drive (22) and the second lifting drive (32) are electric push rods.

4. A dual direction winding machine as claimed in claim 1, wherein: The outer periphery of the first shaft sleeve (25) and the second shaft sleeve (35) is connected with a bearing.

5. A dual direction winding machine as claimed in claim 1, wherein: An elastic reset assembly is arranged between the flat wire clamping plate (29) and the lower wire winding main shaft (27).

6. A dual direction winding machine as claimed in claim 2, wherein: A magnetic adsorption structure is arranged at the butt joint end of the lower wire winding main shaft (27) and the second mandrel (34) of the upper winding unit (3).

7. A dual direction winding machine as claimed in claim 1, wherein: ​

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