Winding system and method

Abstract

The present invention provides a winding system and method. The winding system comprises a first gear, two second gears, a guide needle, and two rotary power sources. The guide needle is fixed on the first gear and used for guiding a wire. The two second gears are separately engaged with the first gear, and the central axes of the two second gears are aligned with each other and both perpendicular to the central axis of the first gear. The two rotary power sources are used for respectively driving the two second gears to rotate, so as to control the guide needle to swing upward, swing downward, rotate counterclockwise or rotate clockwise.

Description

Winding systems and methods Technical Field

[0001] This invention relates to a winding system and method, and more particularly to a motor winding system and method. Background Technology

[0002] In response to performance requirements, electromechanical products are becoming increasingly sophisticated in their design. The goal is to incorporate higher density copper wires into the existing electrode space to increase power per unit area. To meet this requirement, a hooking method is typically used as the winding technique.

[0003] The current winding method brings the guide pin as close as possible to the electrode and moves it according to the shape of the target electrode. During the rising and falling sections of the winding, the direction of the copper wire exiting the winding is perpendicular to and opposite to the direction of the guide pin's movement. This can easily increase the wear of the guide pin and damage to the copper wire's enameled layer under long-term high tension. Summary of the Invention

[0004] This invention proposes a winding system and method to solve the problems of prior art.

[0005] According to some embodiments of the present invention, a winding system includes a first gear, two second gears, a guide pin, and two rotary power sources. The guide pin is fixed to the first gear and is used to guide a single thread. The two second gears respectively mesh with the first gear, wherein the central axes of the two second gears are aligned with each other and are both perpendicular to the central axis of the first gear. The two rotary power sources are used to drive the two second gears to rotate, thereby controlling the guide pin to swing upward, downward, counterclockwise, or clockwise.

[0006] According to some embodiments of the present invention, the winding system further includes: an upper fixed frame on which the two rotary power sources are disposed; a lower fixed frame; two shafts, the lower ends of which are connected to the lower fixed frame and the upper ends of which are respectively connected to the two rotary power sources; and a gear set connected to the two shafts and driven by the two rotary power sources to slide up and down on the two shafts.

[0007] According to some embodiments of the present invention, the gear set includes: two L-shaped frames; two fourth gears respectively disposed on the two shafts and rotatably connected to one side of the two L-shaped frames; two third gears respectively rotatably connected to the other side of the two L-shaped frames and respectively meshing with the two fourth gears; an intermediate body; a first gear rotatably connected to one side of the intermediate body, and a guide pin rotatably connected to the other side of the intermediate body and passing through the intermediate body and fixed to the first gear, so that the guide pin rotates synchronously with the first gear; two second gears respectively rotatably connected to the two L-shaped frames and respectively shafted to the two third gears, and the two second gears respectively rotatably connected to two opposite sides of the intermediate body and both meshing with the first gear; a cantilever frame, one front end of which is fixed to the intermediate body; and two guide wheels disposed at one rear end of the cantilever frame, the first gear being located between the guide pin and the two guide wheels. When winding, the two guide wheels allow the wire to pass through the space between the two guide wheels. The wire enters from an inlet hole of the first gear and exits from an outlet hole of the guide pin.

[0008] According to some embodiments of the present invention, the central axis of the two third gears is perpendicular to the central axis of the two fourth gears, the central axis of the two second gears is aligned with the central axis of the third gear and rotates synchronously, and the two fourth gears are driven by the two rotational power sources to drive the two third gears and the two second gears to rotate respectively.

[0009] According to some embodiments of the present invention, when the two rotary power sources drive the two second gears to rotate in the same direction, the first gear causes the guide pin to swing upward or downward.

[0010] According to some embodiments of the present invention, when the two rotary power sources drive the two second gears to rotate in opposite directions, the first gear causes the guide pin to rotate counterclockwise or clockwise.

[0011] According to some embodiments of the present invention, the guide pin is aligned with the central axis of the first gear, and the guide pin has an elliptical cross section.

[0012] According to some embodiments of the present invention, a winding method includes: guiding a wire from the outlet hole of a guide pin and winding it around a target to be wound, wherein the guide pin is fixed to a first gear and two second gears mesh with the first gear; and using two rotary power sources to drive the rotation of the two second gears to control the movement of the guide pin as follows: the guide pin winds the wire around the target to be wound; when the guide pin rises on one side of the target to be wound, the angle between the guide pin and a horizontal plane is a positive angle, wherein the horizontal plane intersects the outlet hole of the guide pin; and when the guide pin descends on the other side of the target to be wound, the angle between the guide pin and the horizontal plane is a negative angle.

[0013] According to some embodiments of the present invention, when the two rotary power sources drive the two second gears to rotate in the same direction, the first gear causes the guide pin to swing upward or downward.

[0014] According to some embodiments of the present invention, when the two rotary power sources drive the two second gears to rotate in opposite directions, the first gear causes the guide pin to rotate counterclockwise or clockwise.

[0015] According to some embodiments of the present invention, the winding method further includes: passing the wire between a pair of guide wheels, the first gear being located between the guide pin and the pair of guide wheels, the guide pin being aligned with the central axis of the first gear.

[0016] In summary, the winding system and method of the present invention use two motors to drive gears to form a composite mechanism of guide pin swing angle and rotation. The goal is to allow the guide pin to not only rotate but also swing at a suitable angle as it travels along its path. When the guide pin moves horizontally, in addition to shortening the distance between the lead wire and the electrode through the swing angle, it can also rotate, maintaining the long side of the guide pin stably facing the copper wire lead direction. This simultaneously reduces tension fluctuations and minimizes wire routing disorder.

[0017] The above description will be given in detail below with reference to the embodiments, and a further explanation of the technical solution of the present invention will be provided. Attached Figure Description

[0018] To make the above and other objects, features, advantages and embodiments of the present invention more apparent and understandable, the accompanying drawings are described below:

[0019] Figure 1 is a perspective view of a winding system according to an embodiment of the present invention;

[0020] Figure 2 is a perspective view of a gear assembly according to an embodiment of the present invention;

[0021] Figure 3 is a perspective view of a gear assembly according to an embodiment of the present invention from another angle;

[0022] Figure 4 is an enlarged view of a portion of the gear set and guide pin according to an embodiment of the present invention;

[0023] Figures 5 to 8 are diagrams illustrating the relationship between the gear set operation and the guide pin according to an embodiment of the present invention; and

[0024] Figure 9 is a perspective view of the guide pin winding around the target electrode according to an embodiment of the present invention;

[0025] Figure 10 is a planar schematic diagram of the guide pin winding around the target electrode according to an embodiment of the present invention;

[0026] Figure 11 is a schematic diagram showing the positive angle between the guide pin and the horizontal plane according to an embodiment of the present invention; and

[0027] Figure 12 is a schematic diagram of the negative angle between the guide pin and the horizontal plane according to an embodiment of the present invention.

[0028] Reference numerals in the attached drawings: 100: Winding system; 101: Lower fixed frame; 102: Upper fixed frame; 104a: Rotary power source; 104b: Rotary power source; 106a: Shaft; 106b: Shaft; 110: Gear set; 111a: L-shaped frame; 111b: L-shaped frame; 112a: Fourth gear; 112b: Fourth gear; 114a: Third gear; 114b: Third gear; 115: Intermediate body; 116a: Second gear; 116b: Second gear; 116a': Central shaft; 116b ': Central shaft 117a: Guide wheel 117b: Guide wheel 118: First gear 118a: Central shaft 118b: Inlet hole 119: Cantilever frame 120: Guide pin 120a: Outlet hole 130: Wire 140a: Upper pole changing rotation section 140b: Lower pole changing rotation section 140c: Rising swing angle section 140d: Falling swing angle section 150: Motor 152: Target electrode 152a: Insulating protrusion 152b: Insulating protrusion HL: Horizontal plane A1: Positive included angle A2: Negative included angle Detailed Implementation

[0029] To provide a more detailed and complete description of the invention, reference can be made to the accompanying drawings and the various embodiments described below, in which the same numbers represent the same or similar elements. Furthermore, well-known elements and steps are not described in the embodiments to avoid unnecessarily limiting the invention. In the embodiments and claims, unless specifically defined herein, "a" and "the" may refer to one or more.

[0030] Please refer to Figure 1, which shows a perspective view of a winding system 100 according to an embodiment of the present invention. The winding system 100 includes an upper fixed frame 102, a lower fixed frame 101, a guide pin 120, a gear set 110, two rotary power sources (104a, 104b), and two shafts (106a, 106b). The two rotary power sources (104a, 104b) are disposed on the upper fixed frame 102. The lower ends of the two shafts (106a, 106b) are connected to the lower fixed frame 101, and the upper ends of the two shafts (106a, 106b) are respectively connected to the rotary power sources (104a, 104b). The gear set 110 is connected to the two shafts (106a, 106b) and can slide up and down on the shafts by being driven by the two rotary power sources (104a, 104b). The movement of the guide pin 120 is controlled by the operation of the gear set 110.

[0031] Please refer to Figures 2 and 3. Figure 2 is a perspective view of the gear set 110 according to one embodiment of the present invention, and Figure 3 is a perspective view of the gear set 110 according to another embodiment of the present invention. The gear set 110 is used to control the movement of the guide needle 120 so that the wire 130 output from the wire outlet hole 120a of the guide needle 120 can be properly guided. The left and right fourth gears (112a, 112b) of the gear set 110 are respectively mounted on the two shafts (106a, 106b) and are rotatably connected to one side of the two L-shaped frames (111a, 111b). The left and right third gears (114a, 114b) of the gear set 110 are rotatably connected to the other side of the two L-shaped frames (111a, 111b) and respectively mesh with the left and right fourth gears (112a, 112b). The central axes of the left and right third gears (114a, 114b) are perpendicular to the central axes of the left and right fourth gears (112a, 112b), respectively. Driven by two rotary power sources (104a, 104b), the rotation of the left and right fourth gears (112a, 112b) drives the rotation of the left and right third gears (114a, 114b), respectively. The left and right second gears (116a, 116b) of the gear set 110 are rotatably connected to two L-shaped frames (111a, 111b), and are respectively shaft-connected to the left and right third gears (114a, 114b). In other words, the central axis of the second gear 116a is aligned with the central axis of the third gear 114a and rotates synchronously, and the central axis of the second gear 116b is aligned with the central axis of the third gear 114b and rotates synchronously. The first gear 118 is rotatably connected to one side of the intermediate body 115, and the guide pin 120 is rotatably connected to the other side of the intermediate body 115 and passes through the intermediate body 115 and is fixed to the first gear 118. Therefore, the guide pin 120 rotates synchronously with the first gear 118. The left and right second gears (116a, 116b) are rotatably connected to two opposite sides of the intermediate body 115 and both mesh with the first gear 118. The front end of the cantilever frame 119 is fixed to the intermediate body 115, and the rear end of the cantilever frame 119 is provided with a pair of guide wheels (117a, 117b) for the wire 130 to pass through between the pair of guide wheels (117a, 117b). The first gear 118 is located between the guide pin 120 and the pair of guide wheels (117a, 117b). During winding, the wire 130 enters from the inlet hole 118b of the first gear 118 and exits from the outlet hole 120a of the guide pin 120.

[0032] Please refer to Figure 4, which shows an enlarged view of a portion of the gear set 110 and guide pin 120 according to an embodiment of the present invention. Figure 4 only shows the left and right second gears (116a, 116b), the first gear 118, and the guide pin 120, while removing the intermediate body 115 and the cantilever frame 119 to clearly show their relationship. In some embodiments of the present invention, both the left and right second gears (116a, 116b) mesh with the first gear 118, and the central axes 116a' and 116b' of the second gears 116a and 116b' are aligned with each other and are both perpendicular to the central axis 118a of the first gear 118. In some embodiments of the present invention, the guide pin 120 is aligned with the central axis 118a of the first gear 118. In some embodiments of the present invention, the guide pin 120 has an elliptical cross-section.

[0033] Please refer to Figures 5 to 8, which show the relationship between the operation of the gear set 110 and the guide needle 120 according to an embodiment of the present invention. In Figure 5, when both the left and right second gears (116a and 116b) are driven to rotate clockwise (referring to the direction of the arrows in the figure), the guide needle 120 will be driven to swing upward in the direction of the arrows in the figure due to the interaction between the two second gears (116a and 116b) and the first gear 118. In Figure 6, when both the left and right second gears (116a and 116b) are driven to rotate counterclockwise (referring to the direction of the arrows in the figure), the guide needle 120 will be driven to swing downward in the direction of the arrows in the figure due to the interaction between the two second gears (116a and 116b) and the first gear 118. In summary, when the left and right second gears (116a, 116b) are driven and rotate in the same direction, the guide pin 120 will be driven to swing up or down under the action of the left and right second gears (116a, 116b) and the first gear 118.

[0034] In Figure 7, when the second gear 116a is driven to rotate counterclockwise and the second gear 116b is driven to rotate clockwise (refer to the direction of the arrows in the figure), the interaction between the two second gears (116a, 116b) and the first gear 118 will drive the guide needle 120 to rotate counterclockwise in the direction of the arrows in the figure. In Figure 8, when the second gear 116a is driven to rotate clockwise and the second gear 116b is driven to rotate counterclockwise (refer to the direction of the arrows in the figure), the interaction between the two second gears (116a, 116b) and the first gear 118 will drive the guide needle 120 to rotate clockwise in the direction of the arrows in the figure. In summary, when the left and right second gears (116a, 116b) are driven to rotate in opposite directions, the guide pin 120 will be driven to rotate counterclockwise or clockwise under the action of the left and right second gears (116a, 116b) and the first gear 118.

[0035] In some embodiments of the present invention, all gears of the gear set 110 are bevel gears.

[0036] Please refer to Figures 9 and 10 simultaneously. Figure 9 is a perspective view of the guide needle 120 winding the target electrode 152 of the motor 150 according to an embodiment of the present invention, and Figure 10 is a plan view of the guide needle 120 winding the target electrode 152 (i.e., the target to be wound) according to an embodiment of the present invention. The mechanism for controlling the movement of the guide needle 120 is the winding system 100 described above. The rotation angle of the guide needle 120 around the target electrode 152 in one revolution includes four stages: upper pole-changing rotation segment 140a, lower pole-changing rotation segment 140b, rising swing angle segment 140c, and falling swing angle segment 140d. The upper pole-changing rotation segment 140a is when the guide needle 120 moves above the target electrode 152. The lower pole-changing rotation segment 140b is when the guide needle 120 moves below the target electrode 152. The rising swing angle segment 140c is when the guide needle 120 rises to one side of the target electrode 152. The descending swing angle segment 140d is when the guide pin 120 descends to the other side of the target electrode 152. When the guide pin 120 is in the ascending swing angle segment 140c (e.g., ascending through the electrode gap 154a), the angle between the guide pin 120 and the horizontal plane HL is a positive angle A1 (see Figure 11). When the guide pin 120 is in the upper electrode switching rotation segment 140a, the positive angle A1 between the guide pin 120 and the horizontal plane HL (see Figure 11) is set to allow the guide pin 120 to swing around the insulating protrusion 152a of the target electrode 152. When the guide pin 120 is in the descending swing angle segment 140d (e.g., descending through the electrode gap 154b), the angle between the guide pin 120 and the horizontal plane HL is a negative angle A2 (see Figure 12). When the guide pin 120 is located in the lower pole-changing rotation section 140b, the negative angle A2 between the guide pin 120 and the horizontal plane HL (refer to Figure 12) is set to allow the guide pin 120 to swing around the insulating protrusion 152b of the target electrode 152. When the guide pin 120 is located in the upper pole-changing rotation section 140a and the lower pole-changing rotation section 140b, rotating the guide pin 120 allows the wire 130 to exit along the long side of the ellipse of the guide pin 120 to reduce the probability of breakage of the guide pin 120, and to swing the guide pin 120 around the insulating protrusions 152a and 152b of the target electrode 152, shortening the distance between the exit wire and the electrode, reducing the distance the copper wire falls, and reducing the situation of wire tangle. Although the above embodiment uses the motor electrode as the target to be wound, the target to be wound in the winding system and method of the present invention is not limited to this.

[0037] The winding system and method of the present invention use two motors to drive gears to form a composite mechanism of guide pin oscillation and rotation. This allows the guide pin to not only rotate but also oscillate at a suitable angle as it travels along the path. Based on this design, the following four advantages can be obtained:

[0038] (1) The sway angle method can reduce the angle between the guide pin and the copper wire exit direction, which can reduce the problem of the force being concentrated at the corner of the guide pin due to the excessive copper wire exit angle, thereby improving the winding quality;

[0039] (2) When the guide needle moves horizontally, the guide needle rotated to a horizontal state can be added with an oscillation angle, which can greatly shorten the distance between the wire outlet and the electrode, reduce the distance the copper wire falls and reduce the situation of wire routing disorder.

[0040] (3) Since the guide pin swing angle can reach 180 degrees, it can meet the needs of vertical hanging line;

[0041] (4) Due to the design of the mechanism, the guide pin can rotate while swinging, thus achieving the advantages of rotating the guide pin and the function of reducing tension by swinging. Because of the multiple functions, various functions can be selected for different winding gauges. When the tension of the winding gauge is high, it can be turned on to rotate, swing, or rotate and swing at the same time. When the tension requirement is not high, it can also return to the traditional winding method with fixed guide pin. Users can choose any winding path they need and match it with various functional modules.

[0042] Although the present invention has been disclosed above by way of embodiments, it is not intended to limit the present invention. Any person skilled in the art can make various modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the claims.

Claims

1. A winding system, comprising: a first gear; a guide pin fixed to the first gear and used to guide a wire; and two second gears respectively engaging the first gear, wherein central axes of the two second gears are aligned with each other and are both perpendicular to a central axis of the first gear; and two rotating power sources used to respectively drive the two second gears to rotate, thereby controlling the guide pin to swing upward, swing downward, rotate counterclockwise or rotate clockwise.

2. The winding system according to claim 1, further comprising: an upper fixed frame, wherein the two rotating power sources are disposed in the upper fixed frame; a lower fixed frame; two shafts, wherein lower ends of the two shafts are connected to the lower fixed frame, and upper ends of the two shafts are respectively connected to the two rotating power sources; and a gear set connected to the two shafts and capable of sliding up and down on the two shafts by driving of the two rotating power sources.

3. The winding system according to claim 2, wherein the gear set comprises: two L-shaped frames; two fourth gears respectively disposed on the two shafts and respectively rotatably connected to sides of the two L-shaped frames; two third gears respectively rotatably connected to the other sides of the two L-shaped frames and respectively engaging the two fourth gears; a middle body; the first gear rotatably connected to one side of the middle body, and the guide pin rotatably connected to the other side of the middle body and fixed to the first gear through the middle body, so that the guide pin rotates synchronously with the first gear; the two second gears respectively rotatably connected to the two L-shaped frames and respectively connected to the two third gears, the two second gears respectively rotatably connected to two opposite sides of the middle body and both engaging the first gear; a cantilever frame, wherein a front end of the cantilever frame is fixed to the middle body; and two wire guide wheels disposed at a rear end of the cantilever frame, and the first gear is located between the guide pin and the two wire guide wheels, when winding, the two wire guide wheels are used for the wire to pass between the two wire guide wheels, and the wire enters from an entry hole of the first gear and outputs from an exit hole of the guide pin.

4. The winding system according to claim 3, wherein central axes of the two third gears are respectively perpendicular to central axes of the two fourth gears, the central axes of the two second gears are aligned with the central axes of the third gears and rotate synchronously, and the two fourth gears are respectively driven by the two rotating power sources to respectively drive the two third gears and the two second gears to rotate.

5. The winding system according to claim 1, wherein when rotating directions of the two second gears driven by the two rotating power sources are the same, the first gear makes the guide pin swing upward or swing downward.

6. The winding system according to claim 1, wherein when rotating directions of the two second gears driven by the two rotating power sources are opposite, the first gear makes the guide pin rotate counterclockwise or rotate clockwise.

7. The winding system according to claim 1, wherein the guide pin is aligned with the central axis of the first gear, and the guide pin has an elliptical cross section.

8. A winding method, comprising: guiding a thread to be wound around an object to be wound by a guide needle, wherein the guide needle is fixed to a first gear, and two second gears are engaged with the first gear; and driving rotation of the two second gears by two rotary power sources to control movement of the guide needle as follows: the guide needle winds the thread around the object to be wound; when the guide needle is ascending on one side edge of the object to be wound, the guide needle has a positive angle with a horizontal plane intersecting the thread exit hole of the guide needle; and when the guide needle is descending on the other side edge of the object to be wound, the guide needle has a negative angle with the horizontal plane.

9. The thread winding method of claim 8, wherein when the two rotary power sources drive the two second gears in the same direction, the first gear swings the guide needle upward or downward.

10. The thread winding method of claim 8, wherein when the two rotary power sources drive the two second gears in opposite directions, the first gear rotates the guide needle counterclockwise or clockwise.

11. The wire winding method of claim 8, further comprising: passing the thread between a pair of thread guide wheels, the first gear being located between the guide needle and the pair of thread guide wheels, and the guide needle being aligned with a central axis of the first gear.

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