CN114068170B - Full-automatic production equipment for flat inductor - Google Patents
Full-automatic production equipment for flat inductor Download PDFInfo
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- CN114068170B CN114068170B CN202010770973.9A CN202010770973A CN114068170B CN 114068170 B CN114068170 B CN 114068170B CN 202010770973 A CN202010770973 A CN 202010770973A CN 114068170 B CN114068170 B CN 114068170B
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 31
- 238000004804 winding Methods 0.000 claims abstract description 96
- 239000000463 material Substances 0.000 claims abstract description 52
- 238000005520 cutting process Methods 0.000 claims abstract description 43
- 238000005452 bending Methods 0.000 claims abstract description 39
- 238000012546 transfer Methods 0.000 claims abstract description 25
- 238000007493 shaping process Methods 0.000 claims abstract description 24
- 238000003466 welding Methods 0.000 claims abstract description 21
- 238000012545 processing Methods 0.000 claims abstract description 5
- 230000007246 mechanism Effects 0.000 claims description 33
- 238000003825 pressing Methods 0.000 claims description 24
- 230000033001 locomotion Effects 0.000 claims description 15
- 238000007599 discharging Methods 0.000 claims description 13
- 210000001503 joint Anatomy 0.000 claims description 8
- 230000006698 induction Effects 0.000 claims description 7
- 239000002699 waste material Substances 0.000 claims description 7
- 238000007664 blowing Methods 0.000 claims description 6
- 238000007667 floating Methods 0.000 claims description 6
- 230000007306 turnover Effects 0.000 claims description 2
- 238000010586 diagram Methods 0.000 description 14
- 230000009471 action Effects 0.000 description 10
- 238000004140 cleaning Methods 0.000 description 7
- 238000000034 method Methods 0.000 description 5
- 230000001360 synchronised effect Effects 0.000 description 4
- 238000007514 turning Methods 0.000 description 4
- 238000001514 detection method Methods 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 230000002441 reversible effect Effects 0.000 description 3
- 238000001179 sorption measurement Methods 0.000 description 3
- 230000000903 blocking effect Effects 0.000 description 2
- 238000002788 crimping Methods 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 238000013459 approach Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 210000000078 claw Anatomy 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005674 electromagnetic induction Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000033764 rhythmic process Effects 0.000 description 1
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/071—Winding coils of special form
- H01F41/074—Winding flat coils
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/096—Dispensing or feeding devices
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/10—Connecting leads to windings
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
The invention discloses full-automatic production equipment for a flat inductor coil, which comprises a paying-off unit, a wire feeding unit for realizing constant-speed equidistant wire feeding, a lower winding unit, an upper winding transfer unit which is positioned above the lower winding unit and is used for realizing upper winding and coil transfer and blanking, a rotary conveying unit which is used for carrying the wound coil and moving the wound coil to each subsequent processing station, a shaping unit, a flat feeding and feeding unit, a wire foot bending and cutting unit, a wire foot hot-press welding unit and a flat coil blanking unit which are sequentially arranged around the rotary conveying unit, and a jig material disc receiving unit for receiving products on the flat coil blanking unit to realize automatic material receiving and disc loading. The invention can greatly improve the production efficiency of the flat inductor.
Description
[ Field of technology ]
The invention belongs to the technical field of inductance coil production, and particularly relates to full-automatic production equipment for a flat inductance coil.
[ Background Art ]
The inductor (inductor coil) is an electromagnetic induction element wound with an insulated wire, and is one of the components commonly used in electronic circuits. The manufacturing of the inductance coil comprises winding, bending, shaping, cutting and welding, the efficiency of the winding equipment in the prior art on the coil winding is lower, and full-automatic production equipment of the flat inductance coil is not provided, so that the production efficiency of the flat inductance coil is low.
Therefore, it is necessary to provide a new full-automatic production device for planar inductor coils to solve the above-mentioned problems.
[ Invention ]
The invention mainly aims to provide full-automatic production equipment for the flat inductor coil, which can greatly improve the production efficiency of the flat inductor coil.
The invention realizes the aim through the following technical scheme: the full-automatic production equipment for the flat inductor coil comprises a paying-off unit, a wire feeding unit, a lower winding unit, an upper winding transfer unit, a rotary conveying unit, a shaping unit, a flat feeding and feeding unit, a wire foot bending and cutting unit, a wire foot hot-press welding unit and a flat coil discharging unit, and a jig material disc receiving unit, wherein the wire feeding unit is used for realizing constant-speed equidistant wire feeding, the upper winding transfer unit is arranged above the lower winding unit and is used for realizing upper winding and coil transfer discharging, the rotary conveying unit is used for carrying a coil after winding and moving to each subsequent processing station, the shaping unit, the flat feeding and feeding unit, the wire foot bending and cutting unit, the wire foot hot-press welding unit and the flat coil discharging unit are sequentially arranged around the rotary conveying unit, and the jig material disc receiving unit is used for carrying products on the flat coil discharging unit to realize automatic material receiving and loading.
Compared with the prior art, the full-automatic production equipment for the panel inductance coil has the beneficial effects that: the automatic coil winding machine realizes a series of full-automatic operations such as upper and lower layers of synchronous winding, automatic shaping of coil feet, automatic supply and feeding of flat magnets, cutting of the coil feet, wrapping bending and tearing of the coil feet, welding of the coil feet, final automatic discharging, dishing and outputting, and the like, and has high production efficiency and high production quality.
[ Description of the drawings ]
FIG. 1 is a schematic top view of an embodiment of the present invention;
Fig. 2 is a schematic structural diagram of a wire releasing unit, a wire feeding unit, an upper wire winding transfer unit and a lower wire winding unit according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a wire unwinding unit according to an embodiment of the present invention;
fig. 4 is a schematic structural diagram of a wire feeding unit according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of the structure of the upper and lower winding transfer units according to the embodiment of the invention;
FIG. 6 is a schematic diagram of a lower winding unit according to an embodiment of the present invention;
FIG. 7 is a schematic structural view of an elastic wire clip according to an embodiment of the present invention;
FIG. 8 is an enlarged partial schematic view of an elastic clip according to an embodiment of the present invention;
FIG. 9 is a schematic structural view of a wire clamping and cutting unit according to an embodiment of the present invention;
FIG. 10 is a schematic diagram of a hot air module according to an embodiment of the present invention;
FIG. 11 is a schematic diagram of an upper wire transfer unit in an embodiment of the present invention;
fig. 12 is a schematic view of a part of the structure of the upper winding transfer unit in the embodiment of the invention;
FIG. 13 is a schematic view of a portion of a rotary assembly and a spool assembly according to an embodiment of the present invention;
FIG. 14 is a schematic view showing the structure of a rotary conveying unit according to an embodiment of the present invention;
FIG. 15 is a schematic diagram of a carrier tool according to an embodiment of the present invention;
FIG. 16 is a schematic view of a coil loading station in accordance with an embodiment of the present invention;
FIG. 17 is a schematic diagram of a shaping unit according to an embodiment of the present invention;
FIG. 18 is a schematic view of a plate feeding unit according to an embodiment of the present invention;
FIG. 19 is a schematic top view of a portion of a plate feeding unit according to an embodiment of the present invention;
fig. 20 is a schematic structural view of a coil pin cutting unit according to an embodiment of the present invention;
FIG. 21 is a schematic diagram of a structure of a wire-foot bending and cutting unit according to an embodiment of the present invention;
FIG. 22 is a schematic view of a structure of a crimping elbow according to an embodiment of the present invention;
FIG. 23 is a schematic diagram showing a wire-foot thermocompression bonding unit according to an embodiment of the present invention;
FIG. 24 is a schematic view of a lifting mechanism of a jig bin according to an embodiment of the present invention;
FIG. 25 is a schematic diagram of a blanking unit for a flat coil and a receiving unit for a jig tray according to an embodiment of the present invention;
Fig. 26 is a schematic structural diagram of an inductor blanking station according to an embodiment of the present invention;
fig. 27 is a schematic structural diagram of a fixture cartridge according to an embodiment of the present invention.
[ Detailed description ] of the invention
Examples:
Referring to fig. 1-27, the embodiment is a full-automatic production device 100 for a planar inductor coil, which comprises a paying-off unit 1, a wire feeding unit 2 for realizing constant-speed equidistant wire feeding, a lower winding unit 3, an upper winding transfer unit 4 which is positioned above the lower winding unit 3 and is used for transferring and blanking upper winding and coils, a rotary conveying unit 5 which is used for carrying the coils after winding and moving to each subsequent processing station, a shaping unit 6, a planar feeding and feeding unit 7, a coil wire foot cutting unit 8, a wire foot bending and cutting unit 9, a wire foot hot-press welding unit 10 and a planar coil blanking unit 20 which are sequentially arranged around the rotary conveying unit 5, and a jig material disc receiving unit 30 for receiving products on the planar coil blanking unit 20 to realize automatic material receiving and loading.
The paying-off unit 1 comprises a first servo motor 11, a rotating shaft 12 which is driven to rotate by the first servo motor 11 and is used for supporting a material roll, a lever arm 14, a first wire roller 15 and a second wire roller 16, wherein the middle part of the lever arm 14 is rotatably hinged to a supporting pin shaft 13, the first wire roller 15 and the second wire roller 16 are rotatably arranged at two ends of the lever arm 14, a first sensor 17 and a second sensor 18 are used for detecting the swinging angle range of one end of the lever arm 14, a reset spring 19 is used for pulling the other end part of the lever arm 14 to reset the lever arm 14, and a wire material sequentially bypasses the first wire roller 15 and the second wire roller 16 in an S shape. A pair of wire winding buckles 111 for limiting the wire are provided on the winding path between the rotary shaft 12 and the first wire roller 15. The first servo motor 11 starts paying-off and stops paying-off operations according to sensing signals of the first sensor 17 and the second sensor 18; when the first sensor 17 detects the position signal, the first servo motor 11 stops paying out; when the second sensor 18 detects the position signal, the first servomotor 11 starts paying out.
The wire feeding unit 2 comprises a second servo motor 21, a first movable plate 22 driven by the second servo motor 21 to perform horizontal linear motion, a first wire clamping cylinder 23 fixed on the first movable plate 22, a first clamping jaw 24 driven by the first wire clamping cylinder 23 to perform wire clamping motion, a second wire clamping cylinder 25 which is positioned at the downstream of the moving path of the clamping jaw 24 and fixedly arranged, and a second clamping jaw 26 driven by the second wire clamping cylinder 25 to perform wire clamping motion. The second clamping jaw 26 is provided with a limit stop lever 27 and a winding buckle 28 for limiting and guiding the wire. The work flow of the wire feeding unit 2 is as follows: the wire is output from the paying-off unit 1, then sequentially passes through a first clamping jaw 24, a limiting stop lever 27, a second clamping jaw 26 and a winding buckle 28, and then enters the winding unit, and when the wire is fed, the first clamping jaw 24 clamps the wire and pulls the wire for a set length along the conveying direction under the drive of a second servo motor 21; the second jaw 26 then grips the wire and the first jaw 24 is retracted to the initial grip position and then grips the wire, while the second jaw 26 releases the wire and the first jaw 24 then begins a second pull wire feed action.
The lower winding unit 3 comprises a lower winding die holder 31 fixedly arranged, a rotating seat 33 driven by a third servo motor 32 to rotate around the lower winding die holder 31, an elastic wire clamp 34 fixed on the rotating seat 33, and a driving assembly 35 for driving the elastic wire clamp 34 to open. In this embodiment, a pair of elastic clamps 34 are symmetrically disposed on the rotating base 33. The elastic wire clamp 34 comprises a mounting seat 341 fixed on the rotating seat 33, a first wire clamping plate 342 fixed on the mounting seat 341, a second wire clamping plate 344 hinged on the mounting seat 341 through a pin shaft 343 and matched with the first wire clamping plate 342 for clamping wires, a spring 345 for tightening the first wire clamping plate 342 and the second wire clamping plate 344 to realize wire clamping is connected between the first wire clamping plate 342 and the second wire clamping plate 344, and a wire loosening driving pressing plate 346 driven by a driving component 35 to push down so that the second wire clamping plate 344 swings around the pin shaft 343 to realize wire loosening is arranged on the second wire clamping plate 344. The first wire clamping plate 342 and the second wire clamping plate 344 clamp the wire under the action of the spring 345. The driving assembly 35 comprises a first cylinder 351 and a driving pressing ring 352 which is driven by the first cylinder 351 to move up and down, wherein the driving pressing ring 352 and the loose wire driving pressing plate 346 have an overlapped part in horizontal projection.
The upper winding transfer unit 4 includes a fourth servo motor 41, a second movable plate 42 driven by the fourth servo motor 41 to perform horizontal rectilinear motion, a fifth servo motor 43 fixed to the second movable plate 42, a third movable plate 44 driven by the fifth servo motor 43 to perform up-and-down motion, an upper winding module 45 fixed to the third movable plate 44, and an upper thread clamping unit 46.
The upper winding module 45 includes a rotating assembly 451 rotatably disposed on the third movable plate 44, a sixth servo motor 452 fixed on the third movable plate 44 and driving the rotating assembly 451 to rotate, a winding shaft assembly 453 rotatable synchronously with the rotating assembly 451 and movable up and down with respect to the rotating assembly 451, and a second cylinder 454 fixed on the third movable plate 44 and driving the winding shaft assembly 453 to move up and down; the spool assembly 453 extends through the rotation assembly 451. The rotation assembly 451 is rotatably mounted on a mounting seat 441 on the third movable plate 44 by means of a bearing. A pair of axial strip-shaped grooves 4511 are symmetrically formed in a circumferential surface of the rotating assembly 451, a rotary driving guide post 4531 which radially penetrates through the strip-shaped grooves 4511 is arranged on the spool assembly 453, and the spool assembly 453 can synchronously rotate along with the rotating assembly 451 through the cooperation of the rotary driving guide post 4531 and the strip-shaped grooves 4511, and the spool assembly 453 can axially move up and down relative to the rotating assembly 451. A spool 455 is fixedly provided at the bottom of the spool assembly 453, and a return spring 456 for pressing the spool assembly 453 downward is provided around the spool assembly 453. The top of spool subassembly 453 is provided with a spacing separation blade 457, and the expansion end of second cylinder 454 is provided with a driving piece 458, is provided with a card on the driving piece 458 and goes into spool subassembly 453 upper portion axostylus axostyle periphery and support the U type draw-in groove 459 of holding spacing separation blade 457 lower surface. In another embodiment, the upper portion of the spool assembly 453 may also be provided with an annular recess into which the drive tab 458 snaps to drive the spool assembly 453 up and down. In the winding process, the winding shaft 455 is driven to perform rotary motion through the sixth servo motor 452, and the winding shaft 455 is driven to perform up-and-down motion through the second cylinder 454, so that the winding shaft is used in cooperation with winding and coil blanking.
The upper grip unit 46 includes a third air cylinder 461, a fourth movable plate 462 which is driven by the third air cylinder 461 to move up and down, a third grip air cylinder 463 fixed to the fourth movable plate 462, and a third grip claw 464 which is driven by the third grip air cylinder 463 to perform grip operation.
On the one hand, in the embodiment, the distance that the upper wire clamping unit 46 clamps the wire to move to the wiring position is equal to the distance that the spool assembly 453 carries the product to move from the winding station to the coil feeding position, so that the beat of the action flow is reduced, and the winding efficiency is improved; on the other hand, the ratio of the speed at which the elastic wire clamp 34 clamps the wire to rotate around the spool 455 to the rotational speed of the spool 455 is 2:1; and the rotation directions of the two are the same. The number of coils of the upper layer winding and the lower layer winding is guaranteed to be the same by controlling the lower winding speed and the upper winding speed to be 2:1.
The lower winding unit 3 and the upper winding transfer unit 4 are further provided with a wire clamping and cutting unit 36, a hot air module 37 for softening wires fed into the winding unit by blowing hot air, and a first waste wire sucking device 38 for sucking the residual wires cut by the wire clamping and cutting unit 36.
The thread-clipping and thread-cutting unit 36 includes a fourth air cylinder 361, a fifth movable plate 362 driven by the fourth air cylinder 361 to perform horizontal rectilinear motion, a thread-clipping module 363 and a thread-cutting module 364 fixed on the fifth movable plate 362. The clamping module 363 includes a fourth clamping cylinder 3631 and a fourth clamping jaw 3632 driven by the fifth movable plate 362 to clamp or open. The thread cutting module 364 comprises a thread cutting cylinder 3641 and a thread cutting knife 3642 driven by the thread cutting cylinder 3641 to perform thread cutting action.
The hot air module 37 comprises a rotary disk 371 rotatably clamped in an annular groove of a supporting roller group 375, a hot air gun 372 fixed in the center of the rotary disk 371, an arc-shaped blowing needle 373 fixed at the end of the hot air gun 372, and a fifth air cylinder 374 driving the rotary disk 371 to swing.
The working flow of the winding unit is as follows: the upper wire clamping unit 46 pulls the wire from the wire pulling position to the wire connecting position, wherein one elastic wire clamp 34 receives and clamps the free end of the wire; then the upper wire clamping unit 46 returns to the wire pulling position, and simultaneously, the upper wire winding module 45 returns to the wire winding position and is positioned right above the lower wire winding die holder 31, and the wire winding shaft 455 stretches out of the bottom to prop against the upper surface of the lower wire winding die holder 31; the elastic wire clamp 34 rotates around the winding shaft 455 for one circle to form a coil, then the winding shaft 455 and the elastic wire clamp 34 rotate in the same direction, and the rotation speed of the elastic wire clamp 34 is twice the rotation speed of the winding shaft 455, so that the synchronous winding action of the same coil numbers on the upper layer and the lower layer is completed; after winding is completed, the elastic wire clamp 34 for clamping the free end of the wire rod rotates to a wire cutting position and releases the wire rod, and the wire rod free end is clamped by the wire clamping module 363, at the moment, the other elastic wire clamp 34 is positioned at the wire connecting position, the wire rod is clamped by the upper wire clamping unit 46 at the wire pulling position, and then the redundant wire and the position connected with the input end of the wire rod are cut through the wire cutting module 364; the wire clamping module 363 loosens the wire and sucks the sheared waste wire away by the first waste wire sucking device 38; the spool 455 in the spool assembly 453 is lifted up, the coil wound around the spool 455 is lifted up in synchronization, and then the coil is moved from the winding position to the feeding position by the horizontal movement and put into the rotary conveying unit 5, and in this transferring process, the upper wire clamping unit 46 clamps the new free end of the wire in synchronization to perform the wire pulling action of the next winding cycle, and the winding transfer and feeding of the next product are performed.
The rotary transport unit 5 includes a rotary transport disk 51 that performs a rotary motion, and a plurality of carrying jigs 52 that are annularly provided on the rotary transport disk 51. The bearing jig 52 includes a slide rail 521 fixed on the rotary conveying tray 51, a bearing plate 522 sliding on the slide rail 521, and a first return spring 524 having one end connected to the bearing plate 522 and the other end connected to a fixed seat 523. The bearing plate 522 is provided with at least two bearing grooves 525 and elastic positioning columns 526 with upper and lower elastic floating functions, and the top ends of the elastic positioning columns extend into the bearing grooves 525. The bearing jig 52 in this embodiment has the bearing plate 522 with the left-right floating function, the bearing groove 525 is arranged on the bearing plate 522, and the bearing groove 525 is arranged into at least two parts, so that multiple products at the same feeding position can be gradually fed by pushing the bearing plate 522, and in the subsequent processing operation of the inductance coil, multiple products are simultaneously operated, thereby laying an important foundation for greatly improving the production efficiency of the production line.
In this embodiment, a coil feeding station, a wire leg flattening and shaping station, a flat plate feeding station, a wire leg cutting station, a wire leg bending and cutting station, a welding station and an inductance discharging station are sequentially arranged around the rotary conveying unit 5, and the upper wire winding transfer unit 4 and the lower wire winding unit 3 are in butt joint with the coil feeding station; the shaping unit 6 is arranged at a stitch flattening shaping station; the flat plate feeding unit 7 is in butt joint with a flat plate feeding station; the coil wire foot cutting unit 8 is arranged at a wire foot cutting station; the wire leg bending and cutting unit 9 is arranged at a wire leg bending and cutting station; the wire foot hot-press welding unit 10 is arranged at a welding station; the plate coil blanking unit 20 is disposed at the inductor blanking station. A product detection station for detecting whether residual product exists in the bearing jig 52 is also arranged between the inductance blanking station and the coil feeding station, and a detection camera (not labeled in the figure) is arranged on the product detection station.
A jig horizontal driving mechanism 53 for driving the bearing plate 522 to float left and right is arranged below the rotary conveying unit 5 at the coil feeding station; the coil loading station, the inductor unloading station and the welding station are all provided with a pushing mechanism 54 for pushing up the elastic positioning column 526 in the bearing jig 52. The horizontal driving mechanism 53 of the jig comprises a rotary air cylinder 531 and a poking rod 532 driven by the rotary air cylinder 531 to swing, and the upper part of the poking rod 532 is propped against the bearing plate 522. The pushing mechanism 54 includes a sixth cylinder 541, a sixth movable plate 542 that moves up and down driven by the sixth cylinder 541, and a jack 543 fixed to the sixth movable plate 542 and corresponding to the position of the elastic positioning column 526. The elastic positioning column 526 is jacked up by the jacking mechanism 54, so that on one hand, the coil can be loaded and placed in the material bearing groove 525 by being matched with the up-down telescopic motion of the winding shaft 455 of the upper winding transfer unit 4; on the other hand, a bottom support may be provided for the flexible positioning posts 526 to maintain the positional stability of the product during the machining operation; and the product can be ejected out during blanking, so that blanking is convenient.
The shaping unit 6 includes an upper shaping die 61 and a lower shaping die 62, and both the upper shaping die 61 and the lower shaping die 62 include a seventh cylinder 611 and a shaping block 612 driven by the seventh cylinder 611 to move up and down.
The flat feeding unit 7 comprises a vibrating disc 71, a receiving plate 72 which is in butt joint with the output end of the vibrating disc 71 and is provided with a material conveying flow channel 721 on the surface, a receiving plate 73 which is in butt joint with the material conveying flow channel 721, an eighth cylinder 74 which drives the receiving plate 73 to horizontally move to realize misplacement material receiving, an output material control assembly 75 which is positioned at the tail end of the material conveying flow channel 721 and controls single output of materials, and a flat feeding transfer mechanism 76 which grabs the materials on the receiving plate 73 onto the rotary conveying unit 5.
The material receiving plate 72 is internally provided with a blowing feeding channel 722 for blowing the material toward the end of the material conveying channel 721. Two receiving grooves 731 are arranged on the receiving plate 73, the receiving grooves 731 are in butt joint with the tail ends of the material conveying flow channels 721, and the material conveying flow channels 721 are in butt joint with the output ends of the vibration plates 71. A shielding plate 77 is disposed above the material conveying channel 721 to limit the height of the material conveying channel 721 and prevent the material from flying out of the material conveying channel 721. The output control assembly 75 includes a baffle plate 751 vertically inserted into the feed channel 721 and blocking an output end of the feed channel 721, an elastic piece 752 connected to the other end of the baffle plate 751 and driving the baffle plate 751 to elastically float in a direction perpendicular to the feed channel 721, a bottom of the elastic piece 752 is fixed on a fixed block 753, an upper end of the elastic piece 752 is inserted into a slot of the baffle plate 751, and a middle portion of the elastic piece 752 is driven by a ninth cylinder 754 to move outwards so that an upper portion of the elastic piece 752 expands outwards, thereby driving the baffle plate 751 to withdraw from the feed channel 721 to discharge. A return spring (not shown) is further disposed below the striker plate 751 at the upper portion of the elastic piece 752, one end of the return spring is connected to the elastic piece 752 and the other end is connected to a fixed seat, and the upper portion of the elastic piece 752 is pulled back to restore the blocking of the striker plate 751 to the material conveying flow path 721. The upper part of the elastic piece 752 realizes an elastic floating function in the direction perpendicular to the feeding flow channel 721 by the reciprocating pushing of the ninth air cylinder 754 and the reset pulling back of the reset spring, and the material control output of the microminiature flat-plate magnet is realized by the elastic floating of the elastic piece 752 at a tiny distance. Because the size of the microminiature flat inductor magnet is very small and is only 1-2 mm, if the material stop plate 751 is directly driven by the air cylinder to control the material, the stroke of the air cylinder cannot be accurately controlled, and the retention space stroke exists frequently in a reciprocating manner, so that the material control cannot be realized. The embodiment meets the output control requirement of microminiature materials by utilizing the elastic floating of the elastic sheet. The plate feeding and transferring mechanism 76 includes a tenth cylinder 761, a seventh movable plate 762 driven by the tenth cylinder 761 to perform horizontal rectilinear motion, an eleventh cylinder 763 fixed on the seventh movable plate 762, and a suction block 764 driven by the eleventh cylinder 763 to perform up-and-down motion, wherein the suction block 764 is provided with suction holes (not labeled in the figure) corresponding to the two receiving slots 731.
The stitch bobbin cutting unit 8 includes a twelfth cylinder 81, and a cutter 82 driven to move up and down by the twelfth cylinder 81.
The stitch bending and cutting unit 9 includes a seventh servo motor 91, an eighth movable plate 92 driven by the seventh servo motor 91 to move left and right, an eighth servo motor 93 fixed to the eighth movable plate 92, a rotary plate 96 driven by the eighth servo motor 93 to rotate about a rotary shaft 95, a stitch clamping unit 97 fixed to the rotary plate 96, and a stitch bending unit fixed to the eighth movable plate 92 and wrapping and bending the stitch along the surface of the inductance magnet. The wire clamping unit 97 includes a fifth wire clamping cylinder 971 and a fifth clamping jaw 972 driven by the fifth wire clamping cylinder 971 to perform opening and clamping actions. The stitch bending unit includes a thirteenth cylinder 94 fixed on the eighth movable plate 92, and a pressing bend 98 driven by the thirteenth cylinder 94 to move up and down. The crimping head 98 has a side pressure surface 981 for pressing the legs against the side surface of the inductor, a lower pressure surface 982 for pressing the legs against the upper surface of the inductor, edges 983 for providing a reverse bending point for the legs to be broken, a front end surface 984, and an inclined support surface 985 for providing space for the legs to be bent in reverse. The side pressure surface 981 and the lower pressure surface 982 are vertically distributed, and an arc groove 986 is arranged at the intersection, so that the side pressure surface 981 can be completely attached to an arc corner surface formed by bending the wire leg when the wire leg is bent by 90 degrees, and the pressing precision and the pressure uniformity of the wire leg are improved. The length of the pressing face 982 in the moving direction of the eighth movable plate 92 is equal to the length of the leg designed to remain on the upper surface of the inductor magnet.
The position of the stitch bending and cutting unit 9 is also provided with a second waste thread sucking device 99, the air suction inlet 991 of the second waste thread sucking device 99 is close to the initial position of the thread clamping unit 97, when the thread clamping unit 97 breaks the stitch, the excessive thread ends are clamped to return to the initial position, then the fifth clamping jaw 972 is loosened, and the excessive thread ends are sucked by the second waste thread sucking device 99.
The working procedure of the stitch bending and cutting unit 9 is as follows: in the initial state, the wire feet of the coil extend horizontally from the lower part of one side surface of the induction magnet, the wire clamping unit 97 is positioned at a 45-degree position (a circle is formed by taking the rotating shaft 95 as the center and taking the rotating radius of the wire clamping unit 97 as the radius), the seventh servo motor 91 drives the eighth movable plate 92 to be close to the coil, and when the free ends of the wire feet extend into the fifth clamping jaw 972, the fifth clamping jaw 972 in the wire clamping unit 97 clamps the end parts of the wire feet; the seventh servo motor 91 continues to drive the eighth movable plate 92 to approach the induction magnet, and at the same time, the wire clamping unit 97 rotates around the rotating shaft 95 (the rotating shaft 95 is used as the rotation center of the wire clamping unit 97 and only moves horizontally), and the end of the wire clamping pin is clamped by the fifth clamping jaw 972 to be turned upwards; when the wire feet are close to the side surface of the induction magnet, the wire pressing bending head 98 moves upwards under the driving action of the thirteenth air cylinder 94, the front end surface 84 of the wire feet pushes the wire feet to be folded upwards, and the wire feet are pressed to be closely attached to the side surface of the induction magnet; at this time, the height difference between the pressing surface 82 of the pressing line bending head 98 and the upper surface of the induction magnet is exactly the same as the thickness of the wire leg; the eighth movable plate 92 continues to move, the line pressing bending head 98 moves horizontally along with the line pressing bending head to continuously push the line feet, the line feet are pressed by the pressing surface 82 to be attached to the upper surface of the induction magnet, and meanwhile, the fifth clamping jaw 972 clamps the end parts of the line feet to follow the whole bending direction of the line feet under the action of horizontal driving and rotary driving; at this time, the length of the wire leg covered by the pressing surface 82 is consistent with the length of the wire leg required to be reserved on the upper surface of the inductor magnet, and at this time, the side pressing surface 81 is just clung to the wire leg on the side surface of the inductor magnet, and pressure maintaining and shaping are carried out on the bent wire leg; when the stitch is folded, the eighth servo motor 93 drives the fifth clamping jaw 972 to clamp the free end of the stitch to rotate reversely (rotate clockwise), and pulls the stitch to tear by taking the end face of the pressing line bending head 98 as a pulling point (reverse bending point), and the rotation radius of the fifth clamping jaw 972 is larger than that of the stitch, so that the stitch can be pulled in the rotation process of the fifth clamping jaw 972; then the fifth clamping jaw 972 is reversed to the initial 45-degree position, and after the wire leg is broken, the seventh servo motor 91 drives the eighth movable plate 92 to retract, so that the bending and breaking operation of the wire leg is completed; the fifth jaw 972 is released and the torn wire is sucked by the second scrap wire sucking means 99.
The stitch thermocompression bonding unit 10 includes a ninth servomotor 101, a ninth movable plate 102 driven by the ninth servomotor 101 to move up and down, a thermocompressor 103 fixed on the ninth movable plate 102, a thermocompression bonding joint 104 elastically provided at the end of the thermocompressor 103, a jig horizontal driving mechanism 53 driving the carrying jig 52 to float horizontally, and a bonding head cleaning unit 105 cleaning the thermocompression bonding joint 104. The head cleaning unit 105 includes a fourteenth cylinder 1051, a housing 1052 driven to move forward and backward by the fourteenth cylinder 1051, and a cleaning brush (not shown) fixed in the housing 1052. The inductor moves to the lower part of the wire foot hot-press welding unit 10 along with the bearing jig 52, the hot-press welding head 104 descends to press the wire feet coated on the surface of the magnet, the material of the outer layer of the wire feet is melted by heating, and then the wire feet are contacted with the surface of the magnet to be cooled, so that welding is realized; then the thermocompression bonding joint 104 slightly lifts up (e.g., lifts up by 1 um), and then the rotary cylinder 531 drives the toggle rod 532 to slightly push the carrier 522, so that relative dislocation occurs between the wire leg and the thermocompression bonding joint 104; then the hot-press-welded joint 104 is lifted up, the fourteenth cylinder 1051 drives the cleaning brush to extend out, the hot-press-welded joint 104 descends and extends into the box body 1052, and the lower surface of the hot-press-welded joint 104 is cleaned through the cleaning brush; the cleaning frequency of the thermocompression bonding head 104 can be flexibly designed according to the requirements.
The plate coil blanking unit 20 includes a tenth servo motor 201, a tenth movable plate 202 driven by the tenth servo motor 201 to move back and forth, a fifteenth cylinder 203 fixed on the tenth movable plate 202, a suction block 204 driven by the fifteenth cylinder 203 to move up and down, and a blanking auxiliary mechanism 205 for preventing the carrier jig 52 from sticking after the suction block 204 adsorbs the product. The suction block 204 is provided with two vacuum suction holes corresponding to the positions of the material bearing grooves 525. The blanking assist mechanism 205 includes a sixteenth cylinder 2051, and a striker plate 2052 that swings driven by the sixteenth cylinder 2051. During blanking, the elastic positioning columns 526 in the bearing jig 52 are jacked up through the jacking mechanism 54, products are also jacked out of the bearing grooves 525, then the product is adsorbed by the suction block 204, the stop plate 2052 swings to the lower side of the products, the elastic positioning columns 526 penetrate through the stop plate 2052, the ejector rods 543 descend, the elastic positioning columns 526 descend and reset under the action of the reset springs, and meanwhile the products are blocked by the stop plate 2052 and cannot descend along with the elastic positioning columns 526, and stay on the suction block 204 under the adsorption of the suction block 204, so that blanking is completed.
The jig tray receiving unit 30 comprises a receiving turnover mechanism 301 for receiving the materials on the flat coil discharging unit 20 to a set number and integrally transferring the materials to a jig tray, a jig transferring mechanism 302 for driving the jig tray to move between a jig receiving station and a jig receiving station, a jig bin 303 for carrying stacked jig trays, a jig bin lifting mechanism 304 for driving the jig bin 303 to move up and down, and a jig inlet and outlet driving mechanism 305 for pushing the full-load jig tray from the jig transferring mechanism 302 into the jig bin 303 and pushing the empty jig tray from the jig bin 303 into the jig transferring mechanism 302.
The stock turning mechanism 301 includes a seventeenth cylinder 3011, a turning plate 3012 driven by the seventeenth cylinder 3011 to turn 180 °, an eighteenth cylinder 3013 fixed to the turning plate 3012, and a stock plate 3014 driven by the eighteenth cylinder 3013 to move up and down. A plurality of vacuum suction grooves which are distributed in a arrayed way are arranged on the material receiving plate 3014. When the material receiving plate 3014 receives materials, vacuumizing adsorption is carried out in the vacuum material absorbing groove, and when the material receiving plate 3014 releases materials onto the jig plate, air leakage is carried out in the vacuum material absorbing groove, so that the adsorption effect on products is canceled, and even the transfer of the products can be assisted by blowing. The receiving and turning mechanism 301 further includes a support bar 3016 for supporting the bottom of the receiving plate 3014 when receiving the products from the blanking transfer mechanism 1. The support rod 3016 is used for supporting the material receiving plate 3014, so that levelness and position stability of the material receiving plate 3014 are guaranteed, and material receiving accuracy is guaranteed.
The jig transfer mechanism 302 includes an eleventh servo motor 3021, and a jig tray positioning support plate 3022 that is driven by the eleventh servo motor 3021 to move left and right and that carries a jig tray.
The jig bin lifting mechanism 304 includes a twelfth servomotor 3041, a support plate 3042 driven by the twelfth servomotor 3041 to move up and down, and a limit column 3043 fixed on the support plate 3042 and limiting opposite sides of the jig bin 303.
The jig housing 303 includes a support base plate 3031, left and right side plates 3032 fixed to the support base plate 3031, an upper cover plate 3033 fixed to the left and right side plates 3032, a plurality of layers of support bars 3034 provided on the inner wall surfaces of the left and right side plates 3031, a plurality of layers of drawer type housings 3035 formed by the support bars 3034, and a back bar 3036 defining the depth of insertion of the jig tray into the drawer type housings 3035 is further provided on the support base plate 3031. The left and right side plates 3032 are further provided with positioning grooves 3037 which are matched with the limiting columns 3043 to realize positioning. Both sides of the jig tray are supported on the supporting bars 3034 and enter and exit the jig bin 303 in a drawer manner. The jig access driving mechanism 305 includes a nineteenth cylinder 3051, an eleventh movable plate 3052 driven by the nineteenth cylinder 3051 to move forward and backward, and a first push plate 3053 and a second push plate 3054 fixed to the front and rear ends of the eleventh movable plate 3052 and located on the front and rear sides of the jig chamber 303. The first push plate 3053 pushes the empty jig tray out of the jig bin 303 onto the jig tray positioning support plate 3022; the second push plate 3054 pushes the full load jig tray from the jig tray positioning support plate 3022 into the jig bin 303.
The working procedure of the full-automatic production equipment 100 for the flat inductor coil in this embodiment is as follows: the paying-off unit 1 flexibly pays off according to the speed and the rhythm of the wire; then, the wire feeding unit 2 is used for feeding wires with equal length and constant speed according to the length of the wire rod required by winding and forming of the single coil; the end of the wire is sent into a winding unit, and the upper layer synchronous winding operation is carried out through the cooperation of an upper winding transfer unit 4 and a lower winding unit 3 to form a coil; the formed coil is moved to a material bearing groove 525 of a bearing jig 52 of the rotary conveying unit 5 by the upper winding transfer unit 4; then, as the rotary conveying disc 51 rotates to a stitch flattening and shaping station, the stitch is flattened from a vertical state to a horizontal state by the shaping unit 6; then rotating to a flat plate feeding station, and outputting two flat plate magnets to a receiving groove 731 of the receiving plate 73 by the flat plate feeding and feeding unit 7, and then sucking the two flat plate magnets to a receiving groove 525 of the bearing jig 52 by the flat plate feeding and transferring mechanism 76; the bearing jig 52 rotates to a stitch cutting station along with the rotary conveying disc 51, and stitch is cut to a set length by the stitch cutting unit 8; then the wire leg bending and cutting unit 9 is rotated to the wire leg bending and cutting station, so that the wrapping and bending of the wire leg and the breaking of the wire leg with the redundant length are completed; then enters a welding station, and the wire pins and the flat plate magnet are welded together through a wire pin hot-press welding unit 10; then rotate to inductance unloading station, take out and place the product that bears in the tool 52 through dull and stereotyped coil unloading unit 20 and put into tool charging tray receipts charging unit 30, accomplish the automatic material sabot that receives of the product of charging tray formula through tool charging tray receipts charging unit 30, finally realize the output with stacked charging tray storehouse form.
The full-automatic production equipment 100 for the flat inductor coil realizes a series of full-automatic operations such as synchronous winding of upper and lower layers of the coil, automatic shaping of wire feet, automatic supply and feeding of flat magnets, cutting of the wire feet, wrapping bending and tearing of the wire feet, welding of the wire feet, final automatic discharging, dishing and outputting, and the like, and has high production efficiency and high production quality.
What has been described above is merely some embodiments of the present invention. It will be apparent to those skilled in the art that various modifications and improvements can be made without departing from the spirit of the invention.
Claims (8)
1. Full-automatic production equipment of dull and stereotyped inductance coil, its characterized in that: the automatic wire winding and coil feeding device comprises a wire paying-off unit, a wire feeding unit for realizing constant-speed equidistant wire feeding, a lower winding unit, an upper winding transfer unit which is positioned above the lower winding unit and is used for transferring upper winding and coil transferring and discharging, a rotary conveying unit which is used for carrying the wound coil and moving the wound coil to each subsequent processing station, a shaping unit, a flat plate feeding and feeding unit, a wire foot bending and cutting unit, a wire foot hot-press welding unit and a flat plate coil discharging unit which are sequentially arranged around the rotary conveying unit, and a jig material disc receiving unit for receiving products on the flat plate coil discharging unit to realize automatic material collecting and disc loading;
The lower winding unit comprises a lower winding die holder fixedly arranged, a rotating seat driven by a third servo motor to rotate around the lower winding die holder, a pair of elastic wire clamps symmetrically fixed on the rotating seat, and a driving assembly for driving the elastic wire clamps to open;
The rotary conveying unit comprises a rotary conveying disc and a plurality of bearing jigs which are annularly arranged on the rotary conveying disc; the bearing jig comprises a sliding rail fixed on the rotary conveying disc, a bearing plate sliding on the sliding rail, and a first reset spring, wherein one end of the first reset spring is connected with the bearing plate, and the other end of the first reset spring is connected with a fixed seat; the bearing plate is provided with at least two bearing grooves and elastic positioning columns, the top ends of the elastic positioning columns extend into the bearing grooves and have an up-down elastic floating function;
The coil feeding station, the wire leg flattening and shaping station, the flat plate feeding station, the wire leg bending and cutting station, the welding station and the inductor blanking station are sequentially arranged around the rotary conveying unit, and the upper winding transfer unit and the lower winding unit are in butt joint with the coil feeding station; the shaping unit is arranged at the stitch flattening shaping station; the flat plate feeding unit is in butt joint with the flat plate feeding station; the wire leg bending and cutting unit is arranged at the wire leg bending and cutting station; the wire leg hot-press welding unit is arranged at the welding station; the flat coil blanking unit is arranged at the inductance blanking station.
2. The full-automatic production device for the planar inductor coil as claimed in claim 1, wherein: the elastic wire clamp comprises a mounting seat fixed on the rotating seat, a first wire clamp plate fixed on the mounting seat, and a second wire clamp plate hinged on the mounting seat through a pin shaft and matched with the first wire clamp plate to clamp wires, a spring for tightening the first wire clamp plate and the second wire clamp plate to clamp wires is connected between the first wire clamp plate and the second wire clamp plate, and a wire loosening driving pressing plate driven by the driving assembly to be pressed down so that the second wire clamp plate swings around the pin shaft to loosen wires is arranged on the second wire clamp plate.
3. The full-automatic production device for the planar inductor coil as claimed in claim 2, wherein: the driving assembly comprises a first air cylinder and a driving pressing ring which is driven by the first air cylinder to move up and down, and the driving pressing ring and the loose wire driving pressing plate are overlapped in horizontal projection.
4. The full-automatic production device for the planar inductor coil as claimed in claim 1, wherein: the upper winding transfer unit comprises a fourth servo motor, a second movable plate driven by the fourth servo motor to perform horizontal linear motion, a fifth servo motor fixed on the second movable plate, a third movable plate driven by the fifth servo motor to perform up-and-down motion, an upper winding module fixed on the third movable plate and an upper wire clamping unit;
The upper winding module comprises a rotating assembly rotatably arranged on the third movable plate, a sixth servo motor fixed on the third movable plate and driving the rotating assembly to rotate, a winding shaft assembly capable of synchronously rotating along with the rotating assembly and moving up and down relative to the rotating assembly, and a second air cylinder fixed on the third movable plate and driving the winding shaft assembly to move up and down; the winding shaft assembly penetrates through the rotating assembly.
5. The full-automatic production device for the planar inductor coil as claimed in claim 1, wherein: the lower winding unit and the upper winding transfer unit are further provided with a wire clamping and cutting unit, a hot air module for softening wires input into the winding station by blowing hot air and a first waste wire sucking device for sucking residual wires cut by the wire clamping and cutting unit.
6. The full-automatic production device for the planar inductor coil as claimed in claim 1, wherein: a jig horizontal driving mechanism for driving the bearing plate to float left and right is arranged below the rotary conveying unit at the coil feeding station; and the coil feeding station, the inductance discharging station and the welding station are respectively provided with a pushing mechanism for pushing the elastic positioning column in the bearing jig upwards.
7. The full-automatic production device for the planar inductor coil as claimed in claim 1, wherein: the stitch bending and cutting unit comprises a seventh servo motor, an eighth movable plate driven by the seventh servo motor to move left and right, an eighth servo motor fixed on the eighth movable plate, a rotary plate driven by the eighth servo motor to rotate, a stitch clamping unit fixed on the rotary plate, and a stitch bending unit fixed on the eighth movable plate and wrapping and bending the stitch along the surface of the induction magnet; the stitch bending unit comprises a thirteenth air cylinder fixed on the eighth movable plate and a line pressing bending head driven by the thirteenth air cylinder to move up and down.
8. The full-automatic production device for the planar inductor coil as claimed in claim 1, wherein: the jig tray receiving unit comprises a receiving turnover mechanism for receiving the materials on the flat coil discharging unit to a set number and then integrally transferring the materials to a jig tray, a jig transferring mechanism for driving the jig tray to move between a jig receiving station and a jig receiving station, a jig bin for bearing stacked jig trays, a jig bin lifting mechanism for driving the jig bin to move up and down, and a jig in-out driving mechanism for pushing the full-load jig tray from the jig transferring mechanism into the jig bin and pushing the empty jig tray from the jig bin into the jig transferring mechanism.
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| CN108400013B (en) * | 2017-12-30 | 2020-06-16 | 芜湖慧盈自动化设备有限公司 | Capacitor coil processing device |
| CN110706918B (en) * | 2019-11-07 | 2024-06-21 | 苏州巨迈科智能科技有限公司 | Inductance coil winding device and use method thereof |
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