A winding jig for a bidirectional pancake coil

Abstract

The utility model discloses a kind of winding clamps for bidirectional pie type coil, including rotary guide pulley mechanism and modular fixture base, modular fixture base is driven by speed reducer motor, rotary guide pulley mechanism includes main correction subassembly and auxiliary correction subassembly, main correction subassembly includes transverse main correction wheel and longitudinal main correction wheel;Auxiliary correction subassembly includes transverse auxiliary correction wheel and longitudinal auxiliary correction wheel, transverse auxiliary correction wheel is elastically mounted on base by mounting seat and spring, the utility model can realize bidirectional self-adapting correction, avoid wire insulation layer abrasion, winding efficiency promotion and reduce plastic deformation.

Description

Technical Field

[0001] This utility model relates to the field of high-current coil technology, specifically a winding clamp for a bidirectional disc coil. Background Technology

[0002] Currently, the disc winding process for high-current coils (such as high-field magnets and power reactors) faces the following technical challenges: 1. High wire rigidity: Copper wire with a cross-sectional area ≥100mm² has high rigidity, making it difficult to achieve precise bidirectional (clockwise + counterclockwise) winding by hand or ordinary winding machine, which can easily lead to wire twisting or insulation layer damage (such as scratches on polyimide film). 2. Lack of angle control: Traditional clamps can only guide the wire in one direction and cannot automatically switch the correction direction when winding in both directions, resulting in uneven stacking of the two layers of coils (misalignment ≥2mm), which affects the uniformity of the magnetic field. 3. Low efficiency: The angle of the wire is repeatedly adjusted manually, and the winding time for a single coil exceeds 8 hours; 4. Stress concentration: When rigid wires are bent, excessive local stress may cause micro-cracks and reduce coil life. Utility Model Content

[0003] The purpose of this invention is to provide a winding clamp for bidirectional disc coils, in order to solve the problems mentioned in the background art, such as high rigidity of existing high-current coil wires, lack of angle control, low efficiency, and stress concentration.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a winding clamp for bidirectional disc coils, comprising a rotating guide wheel mechanism and a modular clamp base. The modular clamp base is driven by a geared motor. The rotating guide wheel mechanism is mounted on the base and includes a main correction component and an auxiliary correction component. The main correction component includes horizontal main correction wheels symmetrically arranged on the left and right and vertical main correction wheels arranged in an alternating pattern. The auxiliary correction component includes horizontal auxiliary correction wheels symmetrically arranged on the left and right and a vertical auxiliary correction wheel mounted above the base. The horizontal auxiliary correction wheels are elastically mounted on the base via mounting seats and springs. The horizontal main correction wheels, vertical main correction wheels, horizontal auxiliary correction wheels, and vertical auxiliary correction wheels are installed sequentially from near to far from the winding turntable.

[0005] The modular fixture base is positioned above the winding machine platform, while the geared motor is positioned below the winding machine platform.

[0006] The base is fixed to the winding machine platform by quick-release bolts.

[0007] The winding turntable is fixed to the modular fixture base using a winding retainer.

[0008] The axial direction of the transverse main straightening wheel is perpendicular to the winding machine platform row; the axial direction of the longitudinal main straightening wheel is parallel to the winding machine platform.

[0009] The lateral auxiliary straightening wheel is perpendicular to the winding machine platform row in axis direction and parallel to the winding machine platform in axis direction.

[0010] Compared with the prior art, the beneficial effects of this utility model are: 1. This utility model can achieve bidirectional adaptive correction: through the rotatable guide wheel mechanism, it automatically adapts to the clockwise / counterclockwise winding direction, maintaining the consistency of the wire bending angle (error ≤ 0.5°). 2. This utility model can achieve insulation protection: the contact surface is made of nylon or polyurethane to avoid wear on the wire insulation layer; 3. This utility model can achieve rapid reversal: no need to disassemble the clamp when switching the winding direction, improving efficiency by more than 50%; 4. This utility model can disperse the stress of the wire: optimize the bending radius of the wire (≥5 times the wire diameter) and reduce plastic deformation. Attached Figure Description

[0011] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a top view of the rotating guide wheel mechanism in this utility model; Figure 3 Schematic diagram of the main correction component in this utility model; Figure 4 This is a schematic diagram of the auxiliary correction component structure in this utility model.

[0012] In the above figures, the components are: 1. Rotary guide wheel mechanism; 2. Modular clamp base; 2. Gear motor; 3. Winding machine platform; 2. Mounting bracket; 4. Base; 1. Main straightening component; 1. Auxiliary straightening component; 1. Horizontal main straightening wheel; 1. Longitudinal main straightening wheel; 1. Horizontal auxiliary straightening wheel; 1. Longitudinal auxiliary straightening wheel; 1. 22. Spring; 1. 23. Mounting seat; 1. 24. Guide column; 1. 25. Detailed Implementation

[0013] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention.

[0014] like Figure 1-4As shown, a winding fixture for bidirectional disc coils includes a rotating guide wheel mechanism 1 and a modular fixture base 2. The winding turntable is fixed on the modular fixture base 2 by a winding fixer. The modular fixture base is driven by a geared motor 2-3. The modular fixture base 2 is positioned above the winding machine platform 3, and the geared motor 2-3 is positioned below the winding machine platform 3. The connection between the geared motor 2-3 and the modular fixture base 2 can be achieved by fixing the output shaft of the geared motor 2-3 to the drive shaft. The drive shaft is rotatably mounted to the winding machine platform 3 through bearings. The drive shaft passes through the winding machine platform 3 and is fixedly connected to the modular fixture base 2. The geared motor 2-3 is fixed below the winding machine platform 3 by a mounting bracket 2-5. The geared motor 2-3 provides the winding power. Copper wire is mounted on the winding turntable. Copper wires of different diameters are fixed on the winding turntable 2-1 using different fixtures. The winding fixer provides precise positioning. The geared motor 2-3 is started, and the geared motor 2-3 drives the modular fixture base 2 and the winding turntable to complete the winding of the copper coil. Different winding turntables are used to wind wires of different diameters. The winding turntables are fixed to the modular fixture base 2 with bolts. Different pressures can be applied by the geared motor 2-3, and the speed and winding direction can be adjusted.

[0015] The rotating guide wheel mechanism 1 is mounted on the base 4, which is fixed to the winding machine platform 3 by quick-release bolts. The rotating guide wheel mechanism 1 includes a main straightening component 1-1 and an auxiliary straightening component 1-2. The main straightening component 1-1 includes transverse main straightening wheels 1-11 arranged symmetrically on the left and right and longitudinal main straightening wheels 1-12 arranged alternately on the top and bottom. The auxiliary straightening component 1-2 includes transverse auxiliary straightening wheels 1-21 arranged symmetrically on the left and right and a longitudinal auxiliary straightening wheel positioned above the base 4. 1-22, the transverse main straightening wheel 1-11 includes two sets of symmetrically arranged grooved guide wheels on the left and right. The transverse main straightening wheel 1-11 is rotatably mounted to the base 4. The axial direction of the transverse main straightening wheel 1-11 is perpendicular to the winding machine platform 3. The longitudinal main straightening wheel 1-12 includes two sets of shaft rollers of different heights on the left and right. The upper and lower sets of longitudinal main straightening wheels 1-12 are staggered. The longitudinal main straightening wheel 1-12 is rotatably mounted to the base 4 through a rotating shaft. The axial direction of the longitudinal main straightening wheel 1-12 is parallel to the winding machine platform 3.

[0016] The transverse auxiliary straightening wheel 1-21 is elastically mounted on the base 4 via the mounting base 1-24 and the spring 1-23. The transverse auxiliary straightening wheel 1-21 includes two sets of symmetrically arranged nylon wheels on the left and right sides. The transverse auxiliary straightening wheel 1-21 is rotatably mounted to the mounting base 1-24 via a rotating shaft. The axial direction of the transverse auxiliary straightening wheel 1-21 is perpendicular to the winding machine platform 3. A spring 1-23 is provided between the outer side of the mounting base 1-24 and the base 4. A guide post 1-25 is provided on the base 4. The guide post 1-25 and the mounting base 1-24 are slidably engaged through guide holes. The longitudinal auxiliary straightening wheel 1-22 includes multiple rollers arranged above the base 4. The rollers are rotatably mounted to the base 4 via a rotating shaft. The axial direction is parallel to the winding machine platform 3.

[0017] The transverse main straightening roller 1-11, the longitudinal main straightening roller 1-12, the transverse auxiliary straightening roller 1-21, and the longitudinal auxiliary straightening roller 1-22 are installed in sequence from near to far relative to the winding turntable 2-1. The winding wire passes in sequence below the longitudinal auxiliary straightening roller 1-22, between the two sets of transverse auxiliary straightening rollers 1-21, between the two sets of longitudinal main straightening rollers 1-12, and between the two sets of transverse main straightening rollers 1-11.

[0018] The transverse main straightening rollers 1-11 are multiple sets of grooved guide rollers (material: alumina ceramic), arranged symmetrically at 90°. The height of the longitudinal main straightening rollers 1-12 is adjusted by bolts to apply pressure to the copper wire, ensuring that the copper wire releases excess stress after passing through the longitudinal main straightening rollers 1-12. After increasing the pressure by the transverse main straightening rollers 1-11 and the longitudinal main straightening rollers 1-12 in different directions, the angle of the wire is corrected, ensuring the overall winding accuracy.

[0019] The transverse auxiliary straightening wheel 1-21 is a nylon wheel that is elastically installed by spring 1-23. The longitudinal auxiliary straightening wheel 1-22 and the transverse auxiliary straightening wheel 1-21 pre-straighten the wire before it enters the main straightening assembly 1-1 in different directions. The center distance between the two sets of transverse auxiliary straightening wheels 1-21 is adjusted by bolts. Different copper wires can be used by changing the center distance between the two wheels. One set of transverse auxiliary straightening wheels 1-21 can be fixed, while the other set of transverse auxiliary straightening wheels 1-21 presses the copper wire with the tension of spring 1-23 to achieve pre-straightening of the copper wire before it enters the assembly.

[0020] The modular clamp base 2 is set on the winding machine platform 3 to accommodate wires of different sizes (width 6~12mm); by changing different winding turntables, it can be used for copper wires of different sizes (round wire or flat wire). The winding ensures that the outer insulation layer of the copper wire is intact, and the intact wire can be wound in the opposite direction with the same bending radius to form the upper coil.

[0021] This invention improves coil winding precision: interlayer misalignment of wire is ≤0.3mm, and magnetic field uniformity is improved by 20%; zero insulation damage: measured insulation resistance value remains ≥1GΩ (ASTM D257 standard); doubled efficiency: single coil winding time is shortened to within 3 hours; extended wire life: bending stress is reduced by 70%; strong compatibility: supports rectangular / circular cross-section copper wire, and is compatible with the modification of existing winding machines.

Claims

1. A winding clamp for a bidirectional disc coil, characterized in that, It includes a rotary guide wheel mechanism and a modular clamp base. The modular clamp base is driven by a geared motor. The rotary guide wheel mechanism is mounted on the base and includes a main straightening component and an auxiliary straightening component. The main straightening component includes horizontal main straightening wheels arranged symmetrically on the left and right and vertical main straightening wheels arranged in an alternating pattern on the top and bottom. The auxiliary straightening component includes horizontal auxiliary straightening wheels arranged symmetrically on the left and right and vertical auxiliary straightening wheels mounted on the base. The horizontal auxiliary straightening wheels are elastically mounted on the base by mounting seats and springs. The horizontal main straightening wheels, vertical main straightening wheels, horizontal auxiliary straightening wheels and vertical auxiliary straightening wheels are installed in sequence from near to far from the winding turntable.

2. A winding clamp for a bidirectional disc coil according to claim 1, characterized in that, The modular fixture base is positioned above the winding machine platform, while the geared motor is positioned below the winding machine platform.

3. A winding clamp for a bidirectional disc coil according to claim 1, characterized in that, The base is fixed to the winding machine platform by quick-release bolts.

4. A winding clamp for a bidirectional disc coil according to claim 1, characterized in that, The winding turntable is fixed to the modular fixture base using a winding retainer.

5. A winding clamp for a bidirectional disc coil according to claim 1, characterized in that... The axial direction of the transverse main straightening wheel is perpendicular to the winding machine platform row; the axial direction of the longitudinal main straightening wheel is parallel to the winding machine platform.

6. A winding clamp for a bidirectional disc coil according to claim 1, characterized in that, The lateral auxiliary straightening wheel is perpendicular to the winding machine platform row, while the longitudinal auxiliary straightening wheel is parallel to the winding machine platform.

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