Inductive zigzag coil pre-folding forming device

Abstract

The utility model discloses a kind of inductance U-shaped coil pre-folding forming equipment, it is related to inductance U-shaped coil preparation technical field, including rack, control system is set on rack, metal segment feeding station, metal segment both sides pre-folding station, U-shaped coil forming station, U-shaped coil unloading station, circulating operation mechanism and multiple forming cooperation mould;Metal segment both sides pre-folding station is provided with metal segment both sides pre-folding mechanism;U-shaped coil forming station is provided with U-shaped coil forming mechanism;The design of circulating operation mechanism, multiple forming cooperation mould, metal segment both sides pre-folding mechanism and U-shaped coil forming mechanism, by pre-folding forming key change molding mode, and can be sequentially and circularly operated to metal segment feeding station, metal segment both sides pre-folding station, U-shaped coil forming station, U-shaped coil unloading station with forming cooperation mould, effectively guarantee molding quality and production efficiency.

Description

Technical Field

[0001] This utility model relates to the field of inductor zigzag coil preparation technology, and in particular to an inductor zigzag coil pre-folding forming equipment. Background Technology

[0002] In the manufacturing process of inductors, some types of inductors require the use of a Z-shaped coil. A Z-shaped coil has a central bend and two side bends.

[0003] Currently, most coil forming processes utilize spring machines or similar mechanisms. These existing spring machine or similar mechanism-based forming technologies are single-mold processes, where all steps are completed using a single mold. This makes speeding up the process difficult and results in significant flatness errors. Consequently, these technologies suffer from low efficiency, high waste generation, and production efficiency that cannot meet current requirements, necessitating urgent improvement. Utility Model Content

[0004] To overcome the shortcomings mentioned above, this utility model aims to provide a technical solution that can solve the aforementioned technical problems.

[0005] To achieve the above objectives, this utility model provides the following technical solution: an inductor U-shaped coil pre-folding forming equipment, including a frame, on which a control system, a metal segment feeding station, metal segment pre-folding stations on both sides, a U-shaped coil forming station, a U-shaped coil unloading station, a circulating mechanism, and multiple forming and matching molds are provided; The circulating mechanism is used to sequentially and cyclically move the forming and fitting mold to the metal segment loading station, the metal segment pre-folding station on both sides, the zig-shaped coil forming station, and the zig-shaped coil unloading station. The forming and fitting mold is used to place the metal segment; The two sides of the metal segment are equipped with a pre-bending mechanism for the metal segment. The pre-bending mechanism is used to bend the metal segment on the forming mold that is moved to the two sides of the metal segment pre-bending station to obtain a pre-bent metal segment. The zig-shaped coil forming station is equipped with a zig-shaped coil forming mechanism, which is used to bend and form the pre-bent metal segment on the forming mold that is moved to the zig-shaped coil forming station to obtain the zig-shaped coil.

[0006] A further technical solution of this utility model: The circulating operating mechanism includes an indexing plate, and multiple forming and matching molds are arranged in a ring at intervals on the turntable of the indexing plate.

[0007] A further technical solution of this utility model: the forming and fitting mold is provided with side bending fitting mold cores for fitting the two sides of the bent metal segment, and a middle bending fitting mold core for fitting the middle section of the bent metal segment.

[0008] A further technical solution of this utility model: the pre-bending mechanism on both sides of the metal segment includes a two-sided bending stamping die that cooperates with the forming die, and a two-sided bending drive assembly that drives the two-sided bending stamping die.

[0009] A further technical solution of this utility model: The Z-shaped coil forming mechanism includes an intermediate bending stamping die that cooperates with the forming mold, and an intermediate bending drive assembly that drives the intermediate bending stamping die.

[0010] Further technical solution of this utility model: The frame is also provided with a metal wire feeding mechanism, a metal wire cutting mechanism and a metal segment posture adjustment mechanism; The metal wire feeding mechanism is used to transport the metal wire to the metal wire cutting mechanism; The metal wire cutting mechanism is used to cut the metal wire fed by the metal wire feeding mechanism to obtain metal segments; The metal segment posture adjustment mechanism receives the metal segments cut by the metal wire cutting mechanism and adjusts the orientation and posture of the metal segments so that the metal segments are presented in the specified orientation and posture at the metal segment loading station. in, The metal segment loading station is equipped with a metal segment loading mechanism, which is used to load the metal segment presented in a specified orientation onto the forming and fitting mold that is moved to the metal segment loading station.

[0011] A further technical solution of this utility model: the metal wire feeding mechanism includes a feeding component; The feeding assembly includes a first electrically controlled clamping unit and a second electrically controlled clamping unit that are spaced apart along the length of the metal wire; The first electronically controlled clamping unit is configured to controllably clamp or de-clamp the metal wire in a direction perpendicular to the wire length direction. The second electronically controlled clamping unit is configured to controllably clamp or de-clamp the metal wire in a direction perpendicular to the wire length direction. The feed assembly also includes an electrically controlled moving unit, which drives one of the electrically controlled clamping units to move along the line length direction.

[0012] The first electrically controlled clamping unit, the second electrically controlled clamping unit, and the metal wire cutting mechanism are arranged sequentially at intervals along the length of the metal wire.

[0013] A further technical solution of this utility model: The metal wire cutting mechanism includes a punching die and a punching drive assembly for driving the punching die to perform punching.

[0014] A further technical solution of this utility model: The metal segment posture adjustment mechanism includes a vibratory plate, which is configured to receive the metal segment cut and falling by the punching die.

[0015] A further technical solution of this utility model: The Z-shaped coil unloading station is provided with a Z-shaped coil unloading mechanism, which is used to unload the Z-shaped coil on the forming mold that is moved to the Z-shaped coil unloading station.

[0016] Compared with the existing technology, the beneficial effects of this technical solution are: the design of the circulating mechanism, multiple forming and matching molds, the pre-folding mechanism on both sides of the metal segment and the Z-shaped coil forming mechanism, through the pre-folding forming key change of the forming method, can sequentially and cyclically run the forming and matching molds to the metal segment loading station, the metal segment pre-folding station on both sides, the Z-shaped coil forming station, and the Z-shaped coil unloading station, effectively ensuring forming quality and production efficiency.

[0017] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a schematic diagram of the metal segment feeding mechanism of this utility model; Figure 3 for Figure 2 Enlarged schematic diagram of a local structure at point A; Figure 4 This is a schematic diagram of the Z-shaped coil feeding mechanism of this utility model; Figure 5 This is a schematic diagram of the structure of the first electrically controlled clamping unit, the second electrically controlled clamping unit, and the electrically controlled moving unit of this utility model. Figure 6 This is a schematic diagram of the metal wire cutting mechanism of this utility model. Figure 7 This is a schematic diagram of the pre-folding mechanism on both sides of the metal segment of this utility model; Figure 8 This is a schematic diagram of the structure of the zigzag coil forming mechanism of this utility model; The corresponding labels in the attached diagram are explained as follows: Rack-1, Control System-2 Metal wire feeding mechanism-3, first electrically controlled clamping unit-301, second electrically controlled clamping unit-302, electrically controlled moving unit-303, support frame-304, unwinding motor-305, unwinding shaft-306. Metal wire cutting mechanism-4, punching die-401, punching drive assembly-402. Metal segment attitude adjustment mechanism -5 Metal segment loading station-6, metal segment loading mechanism-601, horizontal moving loading assembly-6011, vertical moving loading assembly-6012, loading electrically controlled gripper-6013. Pre-bending stations on both sides of the metal segment - 7; pre-bending mechanism on both sides of the metal segment - 701; bending stamping die on both sides - 7011; bending drive assembly on both sides - 7012. Z-shaped coil forming station - 8, Z-shaped coil forming mechanism - 801, intermediate bending stamping die - 8011, intermediate bending drive assembly - 8012. Z-shaped coil unloading station - 9, Z-shaped coil unloading mechanism - 901, horizontal moving unloading assembly - 9011, vertical moving unloading assembly - 9012, unloading electrically controlled gripper - 9013, unloading tray - 9014. Circulating mechanism-10, Molding mold-11, side bending mold core-1101, middle bending mold core-1102. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] Please see Figure 1-8 A pre-folding forming device for an inductor coil in the shape of a "Z" includes a frame 1, on which are mounted a control system 2, a metal wire feeding mechanism 3, a metal wire cutting mechanism 4, a metal segment posture adjustment mechanism 5, a metal segment loading station 6, pre-folding stations on both sides of the metal segment 7, a "Z" coil forming station 8, a "Z" coil unloading station 9, a circulating mechanism 10, and multiple forming molds 11.

[0022] The metal wire feeding mechanism 3 is used to transport the metal wire to the metal wire cutting mechanism 4.

[0023] The metal wire cutting mechanism 4 is used to cut the metal wire conveyed by the metal wire feeding mechanism 3 to obtain metal segments.

[0024] The metal segment posture adjustment mechanism 5 receives the metal segments cut by the metal wire cutting mechanism 4 and adjusts the orientation and posture of the metal segments so that the metal segments are presented in the specified orientation and posture at the metal segment loading station 6.

[0025] The circulating mechanism 10 is used to sequentially and cyclically rotate the forming and fitting mold 11 to the metal segment loading station 6, the metal segment pre-folding stations on both sides 7, the Z-shaped coil forming station 8, and the Z-shaped coil unloading station 9.

[0026] The forming mold 11 is used to place the metal segment.

[0027] The metal segment loading station 6 is equipped with a metal segment loading mechanism 601, which is used to load the metal segment presented in a specified orientation to the metal segment loading station onto the forming and fitting mold that is moved to the metal segment loading station.

[0028] The two sides of the metal segment pre-bending station 7 are equipped with a metal segment pre-bending mechanism 701. The metal segment pre-bending mechanism is used to fold the metal segment on the forming mold that is moved to the metal segment pre-bending station, so that the two sides of the metal segment are pre-bent to the corresponding angle to obtain a pre-bent metal segment.

[0029] The zig-shaped coil forming station 8 is equipped with a zig-shaped coil forming mechanism 801. The zig-shaped coil forming mechanism is used to bend and form the pre-bent metal segment on the forming mold that is moved to the zig-shaped coil forming station, so that the pre-bent metal segment is bent into the required zig-shaped coil.

[0030] The zig-shaped coil unloading station 9 is equipped with a zig-shaped coil unloading mechanism 901. The zig-shaped coil unloading mechanism 901 is used to unload the zig-shaped coil on the forming mold that is moved to the zig-shaped coil unloading station, so that the forming mold can regain its placement capacity.

[0031] In some embodiments, the wire feeding mechanism 3 includes a feeding component for feeding the wire along the length of the wire to the wire cutting mechanism 4.

[0032] In some embodiments, the feeding assembly includes a first electrically controlled clamping unit 301 and a second electrically controlled clamping unit 302 that are spaced apart along the length of the metal wire.

[0033] The first electronically controlled clamping unit 301 is configured to controllably clamp or de-clamp the metal wire in a direction perpendicular to the wire length direction.

[0034] The second electronically controlled clamping unit 302 is configured to controllably clamp or de-clamp the metal wire in a direction perpendicular to the wire length direction.

[0035] The feeding assembly also includes an electrically controlled moving unit 303, which drives one of the electrically controlled clamping units (the first electrically controlled clamping unit or the second electrically controlled clamping unit) to move along the line length direction.

[0036] The first electrically controlled clamping unit 301, the second electrically controlled clamping unit 302, and the metal wire cutting mechanism 4 are arranged sequentially at intervals along the length of the metal wire.

[0037] In some embodiments, the electrically controlled moving unit 303 may be configured to drive the first electrically controlled clamping unit 301 to move.

[0038] The metal wire is clamped by the first electrically controlled clamping unit. Then, the electrically controlled moving unit moves the first electrically controlled clamping unit closer to the second electrically controlled clamping unit to convey the metal wire towards the second electrically controlled clamping unit, that is, towards the metal wire cutting mechanism. Next, the second electrically controlled clamping unit clamps the metal wire, and the first electrically controlled clamping unit releases its clamping. Then, the electrically controlled moving unit moves the first electrically controlled clamping unit away from the second electrically controlled clamping unit, and upon reaching its designated position, the first electrically controlled clamping unit clamps the metal wire, and the second electrically controlled clamping unit releases its clamping. This conveying cycle is repeated when further conveying is required.

[0039] In some embodiments, the first electrically controlled clamping unit 301 uses a cylinder as a drive source, for example. Specifically, the first electrically controlled clamping unit has a first retaining seat, on which a first cylinder is mounted, and a first clamping block corresponding to the first retaining seat is connected to the piston rod of the first cylinder.

[0040] The first cylinder drives the first clamping block in a direction perpendicular to the length of the wire, causing the first clamping block and the first retaining seat to press close to each other, thereby clamping the metal wire located between the first clamping block and the first retaining seat.

[0041] In some embodiments, the second electrically controlled clamping unit 302 uses a cylinder as a drive source, for example. Specifically, the second electrically controlled clamping unit has a second retaining seat connected to the frame, a second cylinder mounted on the second retaining seat, and a second clamping block corresponding to the second retaining seat connected to the piston rod of the second cylinder.

[0042] The second cylinder drives the second clamping block in a direction perpendicular to the length of the wire, causing the second clamping block and the second retaining seat to press close to each other, thereby clamping the metal wire located between the second clamping block and the second retaining seat.

[0043] In some embodiments, the electrically controlled moving unit 303 uses a cylinder as a drive source, for example. Specifically, the electrically controlled moving unit has a third retainer connected to a frame, a third cylinder mounted on the third retainer, and a first retainer connected to the piston rod of the third cylinder.

[0044] The first retaining seat of the first electrically controlled clamping unit 301 is connected to the first retainer. The third cylinder drives the first retainer in the same direction as the linear length direction, so that the first electrically controlled clamping unit on the first retainer moves closer to or further away from the second electrically controlled clamping unit along the linear length direction.

[0045] In some embodiments, the wire feeding mechanism 3 further includes a support frame 304, on which an unwinding motor 305 and an unwinding shaft 306 are rotatably connected.

[0046] A spool with metal wire can be fixed on an unwinding shaft 306, and an unwinding motor 305 drives the unwinding shaft 306 to unwind.

[0047] In some embodiments, the unwound metal wire is clamped by the first electrically controlled clamping unit 301, and the first electrically controlled clamping unit 301, the second electrically controlled clamping unit 302, and the electrically controlled moving unit 303 work together to achieve automatic unwinding and feeding.

[0048] In some embodiments, the metal wire cutting mechanism 4 includes a punching die 401 and a punching drive assembly 402 for driving the punching die to perform punching.

[0049] The punching drive assembly 402 is, for example, a cylinder drive assembly. The punching drive assembly 402 drives the upper punching die of the punching die 401 to move up and down, and in conjunction with the lower punching die of the punching die 401, cuts the metal wire placed horizontally on the lower punching die to obtain a metal segment.

[0050] In some embodiments, the metal segment posture adjustment mechanism 5 includes a vibratory plate, which arranges the metal segments and arranges them in a specified orientation at the arrangement track of the vibratory plate.

[0051] In some embodiments, the metal segments formed after being cut by the punching die 401 on the metal wire constitute the corresponding segments that fall into the vibratory feeder below.

[0052] In some embodiments, the metal segment feeding mechanism 601 includes a horizontal moving feeding component 6011, a vertical moving feeding component 6012, and a feeding electronically controlled gripper 6013. The vertical moving feeding component 6012 is disposed on the moving end of the horizontal moving feeding component 6011, and the feeding electronically controlled gripper 6013 is disposed on the moving end of the vertical moving feeding component 6012.

[0053] The feeding electric control gripper 6013 can grasp the metal segments arranged by the vibratory feeder. The feeding electric control gripper 6013 is driven by the up-down moving feeding component 6012 and the horizontal moving feeding component 6011 to move to the forming and fitting mold and place the metal segment on the mold cavity of the forming and fitting mold.

[0054] In some embodiments, the horizontal moving feeding assembly 6011 is a cylinder guide rail slider assembly, and the slider of the horizontal moving feeding assembly is connected to a horizontal mounting base.

[0055] The vertical moving feeding assembly 6012 is a cylinder guide rail slider assembly set on a horizontal mounting base. The slider of the vertical moving feeding assembly is connected to the upper and lower mounting bases.

[0056] The 6013 electric control gripper for feeding is a pneumatic gripper mounted on the upper and lower mounting bases.

[0057] In some embodiments, the forming mold 11 corresponds to having side bending mold cores 1101 for fitting both sides of the bent metal segment, and a middle bending mold core 1102 for fitting the middle section of the bent metal segment.

[0058] In some embodiments, the pre-bending mechanism 701 on both sides of the metal segment includes a two-side bending stamping die 7011 that cooperates with the forming die, and a two-side bending drive assembly 7012 that drives the two-side bending stamping die.

[0059] The two-sided bending drive assembly 7012 is, for example, a cylinder drive assembly. The two-sided bending drive assembly drives the two-sided bending stamping dies to move down, so as to perform two-sided stamping and bending on the horizontally arranged metal segment on the forming and mating die located below.

[0060] In some embodiments, the zigzag coil forming mechanism 801 includes an intermediate bending stamping die 8011 that cooperates with the forming die, and an intermediate bending drive assembly 8012 that drives the intermediate bending stamping die.

[0061] The intermediate bending drive assembly 8012 is, for example, a cylinder drive assembly. The intermediate bending drive assembly drives the intermediate bending stamping die to perform intermediate bending on the metal segment on both sides of the forming and mating die located below, thereby obtaining a Z-shaped coil.

[0062] In some embodiments, the zigzag coil feeding mechanism 901 includes a horizontal moving feeding component 9011, a vertical moving feeding component 9012, a feeding electronically controlled gripper 9013, and a feeding tray 9014. The vertical moving feeding component 9012 is disposed on the moving end of the horizontal moving feeding component 9011, and the feeding electronically controlled gripper 9013 is disposed on the moving end of the vertical moving feeding component 9012.

[0063] The feeding electric control gripper 9013 can grasp the zig-shaped coil on the forming mold. The feeding electric control gripper 9013 is moved to the feeding tray 9014 by the up-down moving feeding component 9012 and the horizontal moving feeding component 9011, and the zig-shaped coil is placed on the feeding tray 9014.

[0064] In some embodiments, the horizontal moving feeding assembly 9011 is a cylinder guide rail slider assembly, and the slider of the horizontal moving feeding assembly is connected to a horizontal mounting bracket.

[0065] The vertical moving unloading assembly 9012 is a cylinder guide rail slider assembly mounted on a horizontal mounting frame. The slider of the vertical moving unloading assembly is connected to the upper and lower mounting frames.

[0066] The 9013 electric control gripper for unloading is a pneumatic gripper mounted on the upper and lower mounting frames.

[0067] In some embodiments, the circulating mechanism includes, for example, an indexing plate, with multiple molding dies arranged in a ring at intervals on the indexing plate's turntable. The molding dies are rotated to their corresponding work positions.

[0068] Tests have shown that this inductor coil pre-folding forming equipment improves efficiency by ≥10% compared to traditional methods.

[0069] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A pre-folding forming device for an inductor coil in the shape of a "U", characterized in that, It includes a frame, on which are installed a control system, a metal segment feeding station, pre-bending stations on both sides of the metal segment, a Z-shaped coil forming station, a Z-shaped coil unloading station, a circulating mechanism, and multiple forming and matching molds; The circulating mechanism is used to sequentially and cyclically move the forming and fitting mold to the metal segment loading station, the metal segment pre-folding station on both sides, the zig-shaped coil forming station, and the zig-shaped coil unloading station; The forming and fitting mold is used to place the metal segment; The two sides of the metal segment are equipped with a pre-bending mechanism for the metal segment. The pre-bending mechanism is used to bend the metal segment on the forming mold that is moved to the two sides of the metal segment pre-bending station to obtain a pre-bent metal segment. The zig-shaped coil forming station is equipped with a zig-shaped coil forming mechanism, which is used to bend and form the pre-bent metal segment on the forming mold that is moved to the zig-shaped coil forming station to obtain the zig-shaped coil.

2. The inductor U-shaped coil pre-folding forming equipment according to claim 1, characterized in that, The circulating mechanism includes an indexing plate, and multiple forming molds are arranged in a ring at intervals on the turntable of the indexing plate.

3. The inductor U-shaped coil pre-folding forming equipment according to claim 1, characterized in that, The forming and fitting mold is provided with side bending fitting mold cores for fitting the two sides of the bent metal segment, and a middle bending fitting mold core for fitting the middle section of the bent metal segment.

4. The inductor U-shaped coil pre-folding forming equipment according to claim 3, characterized in that, The pre-bending mechanism on both sides of the metal segment includes two bending stamping dies that cooperate with the forming mold, and two bending drive assemblies that drive the two bending stamping dies.

5. The inductor U-shaped coil pre-folding forming equipment according to claim 3, characterized in that, The Z-shaped coil forming mechanism includes an intermediate bending stamping die that cooperates with the forming mold, and an intermediate bending drive assembly that drives the intermediate bending stamping die.

6. The inductor U-shaped coil pre-folding forming equipment according to claim 1, characterized in that, The frame is also equipped with a wire feeding mechanism, a wire cutting mechanism, and a wire segment attitude adjustment mechanism; The metal wire feeding mechanism is used to transport the metal wire to the metal wire cutting mechanism; The metal wire cutting mechanism is used to cut the metal wire fed by the metal wire feeding mechanism to obtain metal segments; The metal segment posture adjustment mechanism receives the metal segments cut by the metal wire cutting mechanism and adjusts the orientation and posture of the metal segments so that the metal segments are presented in the specified orientation and posture at the metal segment loading station. in, The metal segment loading station is equipped with a metal segment loading mechanism, which is used to load the metal segment presented in a specified orientation onto the forming and fitting mold that is moved to the metal segment loading station.

7. The inductor U-shaped coil pre-folding forming equipment according to claim 6, characterized in that, The wire feeding mechanism includes a feeding component; The feeding assembly includes a first electrically controlled clamping unit and a second electrically controlled clamping unit that are spaced apart along the length of the metal wire; The first electronically controlled clamping unit is configured to controllably clamp or de-clamp the metal wire in a direction perpendicular to the wire length direction. The second electronically controlled clamping unit is configured to controllably clamp or de-clamp the metal wire in a direction perpendicular to the wire length direction. The feed assembly also includes an electrically controlled moving unit, which drives one of the electrically controlled clamping units to move along the line length direction; The first electrically controlled clamping unit, the second electrically controlled clamping unit, and the metal wire cutting mechanism are arranged sequentially at intervals along the length of the metal wire.

8. The inductor U-shaped coil pre-folding forming equipment according to claim 7, characterized in that, The metal wire cutting mechanism includes a punching die and a punching drive assembly that drives the punching die to perform punching.

9. The inductor U-shaped coil pre-folding forming equipment according to claim 7, characterized in that, The metal segment posture adjustment mechanism includes a vibratory feeder, which receives the metal segments cut and falling by the punching die.

10. The inductor U-shaped coil pre-folding forming equipment according to claim 1, characterized in that, The zig-shaped coil unloading station is equipped with a zig-shaped coil unloading mechanism, which is used to unload the zig-shaped coils from the forming mold that is moved to the zig-shaped coil unloading station.

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