A winding device for electromagnetic wires in transformer windings

Abstract

This utility model discloses a winding device for electromagnetic wires in transformer windings, relating to the technical field of transformer manufacturing equipment. It includes a fixed frame, a control panel mounted on the inclined end of the fixed frame, a fixed seat at one end of the fixed frame, a servo motor and a stepper motor mounted on the inner wall of the fixed frame, a guide frame mounted at one end of the fixed frame, a screw rotatably mounted on the inner wall of the guide frame, and a long rod mounted on the inner wall of the guide frame. This utility model achieves high wire routing accuracy and stable winding quality. The stepper motor drives the ball screw to move the threaded seat, and the double guidance of the guide rod and the long rod ensures accurate wire routing spacing. The trapezoidal guide seat combined with the sliding wheel limits electromagnetic wire offset, and a displacement sensor compensates for changes in winding diameter in real time, effectively avoiding problems such as electromagnetic wire overlap and excessive gaps, thus improving coil consistency.

Description

Technical Field

[0001] This utility model relates to the field of transformer manufacturing equipment technology, and in particular to a winding device for electromagnetic wires of transformer windings. Background Technology

[0002] Transformer windings are the core component of a transformer, and their winding quality directly affects the transformer's performance and lifespan. During the winding process, it is necessary to ensure that the electromagnetic wires are neatly arranged, the tension is stable, and the coil turns are tightly spaced to reduce eddy current losses and improve insulation performance.

[0003] However, in terms of wire winding accuracy, traditional winding devices mostly use ordinary motors with gear transmission to drive the wire winding mechanism. The transmission gap is large and the straightness control is insufficient, which makes it easy for problems such as layer overlap and uneven gap between turns to occur when winding electromagnetic wire. Although some devices are equipped with guide structures, they cannot adjust the guide height in real time according to the change of winding mold diameter. When winding multi-layer coils, the deviation accumulates significantly, requiring frequent manual intervention and calibration. This not only reduces production efficiency, but also affects the coil consistency due to human operation errors, thereby increasing the eddy current loss when the transformer is running. Utility Model Content

[0004] The purpose of this utility model is to solve the problems existing in the prior art by proposing a winding device for electromagnetic wires of transformer windings.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a winding device for electromagnetic wires of transformer windings, comprising a fixed frame, a control panel mounted on the inclined end of the fixed frame, a fixed seat provided at one end of the fixed frame, a servo motor and a stepper motor mounted on the inner side wall of the fixed frame, a guide frame mounted at one end of the fixed frame, a screw rotatably mounted on the inner wall of the guide frame, a long rod mounted on the inner wall of the guide frame, a threaded seat slidably mounted on the outer wall of the long rod, a first telescopic rod mounted on the upper end of the threaded seat, a trapezoidal guide seat mounted on the extended end of the first telescopic rod, multiple sets of sliding wheels rotatably mounted inside the trapezoidal guide seat, and a displacement sensor mounted on the upper end of the trapezoidal guide seat.

[0006] Preferably, the other end of the screw passes through one end of the fixing frame and is fixed to the output end of the stepper motor, and the other end of the long rod is fixed to one end of the fixing frame.

[0007] Preferably, the outer wall of the screw is threadedly connected to the inner wall of the threaded seat, and the stepper motor, the first telescopic rod, and the displacement sensor are all signal-connected to the control panel.

[0008] Preferably, guide protrusions are installed at both ends of the threaded seat, and guide rods are slidably installed through one end of each set of guide protrusions. The other ends of each set of guide rods are fixed to one end of the fixing frame.

[0009] Preferably, the output end of the servo motor passes through one end of the mounting bracket and is fixed to one end of the mounting base, and the servo motor is connected to the control panel via signal.

[0010] Preferably, a sliding seat is slidably mounted on the front end of the fixing frame, a second telescopic rod is mounted on the front end of the fixing frame, and a tension rod is rotatably mounted on one end of the sliding seat.

[0011] Preferably, a pressure sensor is installed on the outer wall of the tension rod, and both the second telescopic rod and the pressure sensor are connected to the control panel via signal connection.

[0012] Compared with the prior art, the advantages and positive effects of this utility model are as follows: 1. In this utility model, the wire laying accuracy is high and the winding quality is stable. The stepper motor drives the ball screw to move the threaded seat, and the double guidance of the guide rod and the long rod ensures the error of the wire laying spacing. The combination of the trapezoidal guide seat and the sliding wheel can limit the deviation of the electromagnetic wire. The displacement sensor compensates for the change of the winding diameter in real time, effectively avoiding problems such as electromagnetic wire overlap and excessive gap, and improving the consistency of the coil.

[0013] 2. In this utility model, the tension adjustment is precise, the electromagnetic wire performance is protected, the pressure sensor monitors the tension in real time, and the second telescopic rod dynamically adjusts the position of the tension rod to achieve closed-loop control of the tension, avoiding the electromagnetic wire from being stretched due to excessive tension or the winding from being loose due to insufficient tension. It is especially suitable for winding fine-diameter electromagnetic wires. Attached Figure Description

[0014] Figure 1 This utility model provides a three-dimensional structural schematic diagram of a winding device for electromagnetic wires in transformer windings; Figure 2 This utility model provides a partial perspective view of a winding device for electromagnetic wires in transformer windings. Figure 3 This utility model provides a structural schematic diagram of a threaded seat, a guide protrusion, and a trapezoidal guide seat for a winding device for electromagnetic wires of transformer windings; Figure 4 The present invention provides a side view of a fixing frame for a winding device for electromagnetic wires of transformer windings.

[0015] Legend: 1. Fixture; 2. Control panel; 3. Fixture base; 4. Servo motor; 5. Guide frame; 6. Stepper motor; 7. Screw; 8. Threaded seat; 9. Sliding seat; 10. Long rod; 11. First telescopic rod; 12. Guide protrusion; 13. Trapezoidal guide seat; 14. Guide rod; 15. Sliding wheel; 16. Displacement sensor; 17. Second telescopic rod; 18. Tension rod; 19. Pressure sensor. Detailed Implementation

[0016] To better understand the above-mentioned objectives, features, and advantages of this utility model, the present utility model will be further described below with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0017] Many specific details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the present invention is not limited to the specific embodiments disclosed in the following specification.

[0018] Example 1: As Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, this utility model provides a winding device for electromagnetic wires in transformer windings, including a fixed frame 1, a control panel 2 mounted on the inclined end of the fixed frame 1, a fixed seat 3 provided at one end of the fixed frame 1, a servo motor 4 and a stepper motor 6 mounted on the inner side wall of the fixed frame 1, a guide frame 5 mounted at one end of the fixed frame 1, a screw 7 rotatably mounted on the inner wall of the guide frame 5, a long rod 10 mounted on the inner wall of the guide frame 5, a threaded seat 8 slidably mounted on the outer wall of the long rod 10, a first telescopic rod 11 mounted on the upper end of the threaded seat 8, a trapezoidal guide seat 13 mounted on the extended end of the first telescopic rod 11, and the interior of the trapezoidal guide seat 13... Multiple sets of sliding wheels 15 are rotatably installed. A displacement sensor 16 is installed on the upper end of the trapezoidal guide seat 13. The other end of the screw 7 passes through one end of the fixed frame 1 and is fixed to the output end of the stepper motor 6. The other end of the long rod 10 is fixed to one end of the fixed frame 1. The outer wall of the screw 7 is threadedly connected to the inner wall of the threaded seat 8. The stepper motor 6, the first telescopic rod 11 and the displacement sensor 16 are all signal connected to the control panel 2. Guide protrusions 12 are installed at both ends of the threaded seat 8. Guide rods 14 are slidably installed through one end of the two sets of guide protrusions 12. The other ends of the two sets of guide rods 14 are fixed to one end of the fixed frame 1. The output end of the servo motor 4 passes through one end of the mounting bracket 1 and is fixed to one end of the mounting base 3. The servo motor 4 is connected to the control panel 2 via signal.

[0019] The specific settings and functions of this embodiment are described in detail below. The fixed frame 1 serves as the basic support structure of the device. It is made of welded steel profiles and has high strength and stability. Its inclined end (usually the operating side) is designed at an ergonomic angle to facilitate the operator's observation and operation of the control panel 2. The other end is fixed to the ground or workbench with bolts to ensure that the equipment does not shake during operation. The control panel 2 integrates a PLC controller, a touch screen, and an emergency stop button, and is installed on the inclined end of the mounting bracket 1. It can preset winding parameters (such as the speed of the servo motor 4, the moving speed of the stepper motor 6, and the tension threshold), display the real-time operating status of the equipment (such as the number of winding turns, data from the displacement sensor 16, and feedback values ​​from the pressure sensor 19), and achieve automated control of each actuator through signal connections.

[0020] The fixed base 3 is installed at one end of the fixed frame 1 and is rigidly connected to the output end of the servo motor 4 (e.g., fixed by a coupling) to clamp and fix the winding mold. The inner wall of the fixed base 3 is provided with a quick-release locking structure (e.g., radial locking bolts or buckles) to adapt to winding molds of different diameters and ensure that there is no radial runout when the winding mold rotates synchronously with the servo motor 4.

[0021] The servo motor 4 serves as the winding power source and is fixed to the inner wall of the fixed frame 1 via a flange seat. Its output end passes through the fixed frame 1 and is connected to the fixed seat 3. A high-precision servo control system is adopted to ensure that the winding mold rotates evenly and to avoid sudden tension changes in the electromagnetic wire due to speed fluctuations.

[0022] The guide frame 5 is a rectangular frame structure, installed at one end of the fixed frame 1 parallel to the rotation axis of the fixed base 3, and is used to support the screw 7 and the long rod 10. The screw 7 is a high-precision ball screw, with both ends rotatably mounted on the inner wall of the guide frame 5 through bearing seats. One end passes through the fixed frame 1 and is connected to the output end of the stepper motor 6 through a coupling, and the other end is positioned by a deep groove ball bearing. The long rod 10 is a smooth shaft structure, set parallel to the screw 7, with both ends fixed to the guide frame 5 and the fixed frame 1, and is used to limit the rotational freedom of the threaded seat 8, ensuring that it slides only along the axial direction. The stepper motor 6 is fixed to the inner wall of the fixed frame 1 through a bracket, serving as the power source for cable laying. The step angle can be set through the control panel 2 to drive the screw 7 to rotate, thereby driving the threaded seat 8 to move precisely along the long rod 10, realizing stepless adjustment of the cable laying pitch.

[0023] The inner wall of the threaded seat 8 is threaded with the screw 7, and the outer wall is slidably fitted with the long rod 10. Guide protrusions 12 are symmetrically installed at both ends. Two sets of guide protrusions 12 are respectively sleeved on two parallel guide rods 14. The two ends of the guide rods 14 are fixed to the fixing frame 1, further improving the straightness of the threaded seat 8 during movement and preventing wire routing deviation. The first telescopic rod 11 uses a servo electric cylinder (or a high-precision pneumatic cylinder). The cylinder body is fixed to the upper end of the threaded seat 8, and the extended end is connected to a trapezoidal guide seat 13. The telescopic amount can be adjusted via the control panel 2 to adapt to the wire routing height requirements of different diameter winding dies. A guide groove is opened on the inner side of the trapezoidal guide seat 13, and multiple sets of sliding wheels 15 (with wear-resistant rubber coating on the wheel surface) are rotatably installed in the groove. The electromagnetic wire passes through the sliding wheels 15. The left and right deviation of the electromagnetic wire is limited by the trapezoidal structure. The rolling contact of the sliding wheels 15 can reduce the wear of the electromagnetic wire surface. The displacement sensor 16 is installed on the upper end of the trapezoidal guide seat 13 to detect the distance from the winding mold surface in real time. The data is fed back to the control panel 2. When the winding diameter changes (such as multi-layer winding), the extension and retraction of the first telescopic rod 11 is automatically adjusted to ensure that the wire guide position is always accurate.

[0024] Example 2: Figure 1 and Figure 4 As shown, a sliding seat 9 is slidably installed at the front end of the fixed frame 1, a second telescopic rod 17 is installed at the front end of the fixed frame 1, a tension rod 18 is rotatably installed at one end of the sliding seat 9, and a pressure sensor 19 is installed on the outer wall of the tension rod 18. The second telescopic rod 17 and the pressure sensor 19 are both connected to the control panel 2 via signal.

[0025] The overall effect of this embodiment is as follows: the sliding seat 9 is slidably mounted on the front end of the fixed frame 1 (located between the winding mold and the trapezoidal guide seat 13) via a linear guide rail, and can move in a direction perpendicular to the winding axis; the second telescopic rod 17 is a servo electric cylinder, with the cylinder body fixed to the front end of the fixed frame 1 and the extended end connected to the sliding seat 9, used to drive the sliding seat 9 to move to adjust the tension; the tension rod 18 has an arc-shaped structure, with one end rotatably connected to the sliding seat 9 and the other end used to wind the electromagnetic wire (forming a tension adjustment path); the pressure sensor 19 is installed on the outer wall of the tension rod 18 (or at the connection with the sliding seat 9), which detects the pressure of the electromagnetic wire on the tension rod 18 in real time (indirectly reflecting the tension magnitude), and the data is fed back to the control panel 2; when the tension exceeds the set threshold, the control panel 2 controls the extension and retraction of the second telescopic rod 17, and changes the winding angle of the electromagnetic wire by adjusting the position of the tension rod 18 to achieve dynamic tension balance.

[0026] The usage and working principle of this device: Initialization preparation: Clamp the winding mold with the appropriate winding specifications using the quick-release structure of the fixed base 3, and pass the electromagnetic wire sequentially around the tension rod 18 and the sliding wheel 15 of the trapezoidal guide seat 13, with the end fixed to the winding mold. Preset parameters such as winding speed, wire pitch, and tension threshold through the control panel 2; Winding power transmission: Control panel 2 starts servo motor 4, and power is transmitted to fixed base 3 through output end, which drives the winding mold to rotate at a constant speed to complete the basic winding action of electromagnetic wire; Precise wire arrangement control: Stepper motor 6 synchronously drives screw 7 to rotate, and threaded seat 8 moves axially along the double guide structure of long rod 10 + guide rod 14; the first telescopic rod 11 adjusts the height of trapezoidal guide seat 13 in real time according to the change in winding mold diameter detected by displacement sensor 16, and guides the electromagnetic wire to be evenly arranged in conjunction with sliding wheel 15 to avoid overlap or gaps. Dynamic tension balance: Pressure sensor 19 detects the pressure of electromagnetic wire on tension rod 18 in real time (feedback tension value). If it exceeds the threshold, control panel 2 controls the second telescopic rod 17 to push the sliding seat 9 to move, adjust the angle of tension rod 18 to change the winding path of electromagnetic wire, and stabilize the tension. Stop and reset: After reaching the preset number of winding turns, all motors stop running, loosen the fixing seat 3, remove the winding mold and the formed coil, and the equipment is reset.

[0027] The above are merely preferred embodiments of this utility model and are not intended to limit the utility model in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments for application in other fields. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of this utility model without departing from the technical solution of this utility model shall still fall within the protection scope of this utility model.

Claims

1. A winding device for electromagnetic wires in transformer windings, comprising a fixing frame (1), characterized in that: The fixed frame (1) is equipped with a control panel (2) at its inclined end. A fixed seat (3) is provided at one end of the fixed frame (1). A servo motor (4) and a stepper motor (6) are installed on the inner side wall of the fixed frame (1). A guide frame (5) is installed at one end of the fixed frame (1). A screw (7) is rotatably installed on the inner wall of the guide frame (5). A long rod (10) is installed on the inner wall of the guide frame (5). A threaded seat (8) is slidably installed on the outer wall of the long rod (10). A first telescopic rod (11) is installed at the upper end of the threaded seat (8). A trapezoidal guide seat (13) is installed at the extended end of the first telescopic rod (11). Multiple sets of sliding wheels (15) are rotatably installed inside the trapezoidal guide seat (13). A displacement sensor (16) is installed at the upper end of the trapezoidal guide seat (13).

2. The winding device for electromagnetic wire of a transformer winding according to claim 1, characterized in that: The other end of the screw (7) passes through one end of the fixing frame (1) and is fixed to the output end of the stepper motor (6). The other end of the long rod (10) is fixed to one end of the fixing frame (1).

3. A winding device for electromagnetic wire in transformer windings according to claim 2, characterized in that: The outer wall of the screw (7) is threaded to the inner wall of the threaded seat (8), and the stepper motor (6), the first telescopic rod (11) and the displacement sensor (16) are all signal connected to the control panel (2).

4. A winding device for electromagnetic wire of a transformer winding according to claim 1, characterized in that: Both ends of the threaded seat (8) are equipped with guide protrusions (12), and one end of each set of guide protrusions (12) is slidably mounted with a guide rod (14). The other end of each set of guide rods (14) is fixed to one end of the fixing frame (1).

5. A winding device for electromagnetic wire of a transformer winding according to claim 1, characterized in that: The output end of the servo motor (4) passes through one end of the fixing frame (1) and is fixed to one end of the fixing seat (3). The servo motor (4) is connected to the control panel (2) via signal.

6. A winding device for electromagnetic wire of a transformer winding according to claim 1, characterized in that: A sliding seat (9) is slidably installed at the front end of the fixed frame (1), a second telescopic rod (17) is installed at the front end of the fixed frame (1), and a tension rod (18) is rotatably installed at one end of the sliding seat (9).

7. A winding device for electromagnetic wire of a transformer winding according to claim 6, characterized in that: A pressure sensor (19) is installed on the outer wall of the tension rod (18), and both the second telescopic rod (17) and the pressure sensor (19) are connected to the control panel (2) via signal.

Images