CN114420446B

CN114420446B - Winding pin manufacturing process of network filter

Info

Publication number: CN114420446B
Application number: CN202210316412.0A
Authority: CN
Inventors: 郭强; 赵鑫; 唐远奎
Original assignee: Mianyang Juxian Automation Equipment Co ltd
Current assignee: Mianyang Juxian Automation Equipment Co ltd
Priority date: 2022-03-29
Filing date: 2022-03-29
Publication date: 2022-08-16
Anticipated expiration: 2042-03-29
Also published as: CN114420446A

Abstract

The invention belongs to the technical field of network filter manufacturing, and discloses a winding pin manufacturing process of a network filter, which is used for winding enameled wire ends of magnetic rings in the network filter at the inner side end parts of pins, arranging a semi-finished network filter with a plurality of magnetic rings to arrange and fix the wire ends of the enameled wires, and then cutting the corresponding position of each arranged enameled wire end through a wire cutting mechanism to form a notch with the cutting depth not more than 45%; and transferring the cut network filter semi-finished product to a winding mechanism, winding by using a winding head outside the pin, leading the enameled wire head into the end part of the inner side of the pin after the enameled wire head is lifted and a coil is formed on the winding head, and sending the enameled wire into the next procedure after the winding is finished and the detection is qualified.

Description

Winding pin manufacturing process of network filter

Technical Field

The invention belongs to the technical field of network filter manufacturing, and particularly relates to a winding pin manufacturing process of a network filter.

Background

The function of the filter is to allow the signal of a certain part of frequencies to pass through smoothly, while the signal of another part of frequencies is greatly suppressed, and the filter can be regarded as a frequency selection circuit in essence. In a filter, the frequency range through which a signal can pass is called a passband or a passband; conversely, the frequency range in which the signal is greatly attenuated or completely suppressed is called the stop band; the dividing frequency between the pass band and the stop band is called the cut-off frequency; the voltage gain of the ideal filter in the pass band is constant, and the voltage gain in the stop band is zero; a transition band of a certain frequency range exists between the pass band and the stop band of the actual filter.

The network filter comprises a shell and a plurality of pins, wherein the pins are uniformly embedded at the upper end and the lower end of the shell, a magnetic ring is arranged in a groove of the shell, and the magnetic ring is connected with the pins through coil leads. When the filter is used for winding, besides the winding of the inner magnetic ring, the enameled wire is wound on the pin, and the redundant wire is cut off, wherein the winding is performed in the process of winding the pin.

Because the network filters/transformers are all small in size, different models will have different numbers of pins. Each pin is small in size, the winding mode on each pin is different, most of the existing winding processes depend on manual processing, the efficiency is low, the yield is low, and the cost is high.

In order to improve the current situation, some prior arts provide an automatic winding device and process, such as an automatic winding device and a winding method for network transformer production with patent No. CN202110977457.8, in which a winding needle structure is disclosed, which uses the structure of the wire hanging port to hook the enameled wire for winding. However, the size of the wire hanging opening structure is necessarily small because the wire hanging opening structure is required to stably hook the enameled wire for winding, and difficulty is high when the multi-part cooperative winding is carried out at the size and the enameled wire is successfully hooked. The off-hook condition is easy to occur in the actual operation, and the partial pins of the partial network filter after winding are not successfully wound, so that the reworking or the material scrapping is caused.

Meanwhile, the mode of directly hooking the wire and then winding the wire on the pin most easily causes the problem that the enameled wire is scratched and peeled due to the sharp edge of the square pin in the winding process, so that the product is broken down. In addition, in the existing winding system, after the coil is formed on the pin, the excess thread end needs to be removed, and usually, in the process, a manual thread pulling mode is adopted, that is, the thread end is clamped by a tool and swings back and forth to be cut. This kind of mode is not only inefficient, and because pin itself volume is less, great pulling force can lead to pin deformation or wire rod itself to damage, and can't look over the flaw through the naked eye.

Disclosure of Invention

In order to solve the problems in the prior art, the invention provides a winding pin manufacturing process of a network filter, wherein an enameled wire led out from a magnet in the network filter in a semi-finished product state is wound on a pin, so that the yield is improved compared with the prior art, and meanwhile, the production efficiency can be improved through pre-cutting treatment.

The technical scheme adopted by the invention is as follows:

the invention discloses a winding pin manufacturing process of a network filter, which is used for winding the end of an enameled wire of an inner magnetic ring of the network filter at the inner side end of a pin, arranging a semi-finished product of the network filter with a plurality of magnetic rings, arranging and fixing the end of the enameled wire, and then cutting the corresponding position of each arranged end of the enameled wire through a wire cutting mechanism to form a notch with the cutting depth not more than 45%;

and transferring the cut network filter semi-finished product to a winding mechanism, winding by using a winding head outside the pin, leading the enameled wire head into the end part of the inner side of the pin after the enameled wire head is lifted and a coil is formed on the winding head, and sending the enameled wire into the next procedure after the winding is finished and the detection is qualified.

With reference to the first aspect, the present invention provides a first implementation manner of the first aspect, before cutting, the semi-finished network filter is fixed on a jig, and the enameled wire ends are manually sorted out and fixed on the wire clamps of the jig, so as to form a plurality of enameled wire ends side by side on the jig.

With reference to the first aspect, the present invention provides a second embodiment of the first aspect, wherein the enameled wire with the notch is detected after the wire cutting, and the enameled wire with the notch depth greater than 45% is determined as the defect record and removed.

With reference to the second embodiment of the first aspect, the present invention provides a third embodiment of the first aspect, wherein the forming condition and the wire breakage condition of the coil are detected after winding, and the tangential depth is adjusted in a feedback manner according to the detection result.

In combination with the second embodiment of the first aspect, the present invention provides a fourth embodiment of the first aspect, wherein the incision depth ranges from 10% to 40%.

With reference to the first aspect, the present invention provides a fifth implementation manner of the first aspect, wherein the winding head includes a guiding head and a clamp, the clamp clamps the end of the enameled wire and winds the enameled wire around the guiding head for at least one turn to form a coil, and after the coil is formed, the enameled wire is cut off from the notch and separated from the clamp to be led into the inner end of the lead downwards.

With reference to the fifth embodiment mode of the first aspect, the present invention provides a sixth embodiment mode of the first aspect, when winding, the corresponding enameled wire is clamped by the clamp and then lifted upwards, and after the enameled wire is rotated around the guide head to form a coil, the enameled wire is guided onto the pin by the gravity of the coil or by the traction of the clamp, and is disconnected from the tangent line during the falling process.

In combination with the fifth embodiment of the first aspect, the present invention provides a seventh embodiment of the first aspect, wherein the guide head has a tapered section with a cross-sectional dimension decreasing toward a falling direction and a smooth surface, and the enamel wire is wound on the surface of the tapered section.

In combination with the fifth embodiment of the first aspect, the present invention provides an eighth embodiment of the first aspect, wherein the process is performed by a programmable automatic device, and a plurality of network filters are fixed on the same fixture for simultaneous winding.

In combination with the fifth implementation manner of the first aspect, the present invention provides a ninth implementation manner of the first aspect, wherein the winding head is of a retractable structure, when winding the pin, the winding head firstly abuts against the end portion of the corresponding pin, the fixture on one side moves downwards and clamps the enameled wire fixed on the fixture by pressing and shrinking the winding head once, and after the fixture is lifted and winding is completed, the winding head performs secondary pressing to guide the coil onto the pin.

The invention has the beneficial effects that:

(1) according to the invention, the enameled wire outside the magnetic ring on the network filter is clamped and wound on the outside to form the coil through the winding head structure and then is led into the pin, so that the problem of enameled wire damage caused by directly winding the coil on the pin is avoided, and the yield and the production efficiency can be improved;

(2) the wire clamp is matched with the guide head, so that manual or automatic winding is realized;

(3) according to the invention, the inclination angle of the guide head is optimized, so that the varnished wire wound on the guide head can smoothly and stably fall, and the condition that an insulating layer of the varnished wire is invalid or broken can be reduced in the winding process.

Drawings

FIG. 1 is a side view of the entire production system in an embodiment of the present invention;

FIG. 2 is a top view of the overall production system in an embodiment of the present invention;

FIG. 3 is an isometric view of the entire production system in an embodiment of the invention;

FIG. 4 is an enlarged view of portion A of FIG. 3 of the present invention;

FIG. 5 is an enlarged view of portion B of FIG. 3 according to the present invention;

FIG. 6 is a front view of a single independent module in the winding mechanism in an embodiment of the present invention;

FIG. 7 is an isometric view of a single independent module in the winding mechanism in an embodiment of the present invention;

FIG. 8 is an isometric view of a single winding head after assembly in an embodiment of the present invention;

FIG. 9 is an isometric view of an embodiment of the present invention with a single winding head disassembled;

FIG. 10 is a disassembled isometric view of a single guide head assembly in an embodiment of the present invention;

FIG. 11 is a front view of a single guide head in an embodiment of the present invention;

FIG. 12 is a schematic cross-sectional view of a tapered transition section of a pilot head in an embodiment of the invention;

FIG. 13 is an isometric view of a single guide head in an embodiment of the present invention;

FIG. 14 is a process flow diagram of the present invention.

In the figure: 1-an inlet transmission belt, 2-an operation table, 3-a line cutting mechanism, 4-a winding mechanism, 5-an outlet transmission belt, 6-a laser cutter, 7-a jig, 8-a chute, 9-a winding machine shell, 10-a winding translation frame, 11-a winding lifting frame, 12-a winding part, 13-a guide head, 13.1-a socket, 14-a clamp and 15-a manual table.

Detailed Description

The invention is further explained below with reference to the drawings and the specific embodiments.

In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are some embodiments of the present application, but not all embodiments. The components of the embodiments of the present application, generally described and illustrated in the figures herein, can be arranged and designed in a wide variety of different configurations.

Thus, the following detailed description of the embodiments of the present application, as presented in the figures, is not intended to limit the scope of the claimed application, but is merely representative of selected embodiments of the application. All other embodiments obtained by a person of ordinary skill in the art based on the embodiments in the present application without making any creative effort belong to the protection scope of the present application.

It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined and explained in subsequent figures.

In the description of the present application, it should be noted that if the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. are used for indicating the orientation or positional relationship based on the orientation or positional relationship shown in the drawings or the orientation or positional relationship which is usually placed when the product of the application is used, the description is only for convenience and simplicity, and the indication or suggestion that the referred device or element must have a specific orientation, be constructed in a specific orientation and be operated, and thus, should not be construed as limiting the present application. Furthermore, the appearances of the terms "first," "second," and the like in the description herein are only used for distinguishing between similar elements and are not intended to be construed as indicating or implying relative importance.

Furthermore, the terms "horizontal", "vertical" and the like when used in the description of the present application do not require that the components be absolutely horizontal or overhanging, but may be slightly inclined. For example, "horizontal" merely means that the direction is more horizontal than "vertical" and does not mean that the structure must be perfectly horizontal, but may be slightly inclined.

In the description of the present application, it should also be noted that unless otherwise explicitly stated or limited, the terms "disposed," "mounted," "connected," and "connected" should be construed broadly and may include, for example, a fixed connection, a detachable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in this application will be understood to be a specific case for those of ordinary skill in the art.

Example (b):

the embodiment discloses a manufacturing process of a network filter, which is mainly used for a pin winding processing process of the network filter.

First, the production process and the corresponding product related to the system in the embodiment need to be briefly described for the support and explanation of the following contents.

The network filter is a miniature semiconductor element with a shell, a plurality of magnetic rings are arranged in the shell, a single or a plurality of enameled wires are wound on the magnetic rings to form an inductance element, and the inductance element is connected with an external circuit through pins so as to achieve the corresponding technical effect.

And the magnetic ring can be led out of the wire ends of at least two enameled wires, the wire ends have a certain extension length, and in the prior art, the wire ends are led out of the shell as required after the magnetic ring is arranged in the shell. At the moment, the pins on the two sides of the shell are fixed, the wire ends penetrate through the pins and extend outwards for a certain length, and then the wire ends are wound on the end parts of the inner sides of the corresponding pins through manual or automatic equipment, so that a good connection effect is formed. And finally, fixing the coil at the inner end part of the pin by processing modes such as viscose and the like to realize stable electric connection with the pin.

The above process is a winding process, and the system in this embodiment is mainly a set of production system optimized for the process. The network filter is still in a semi-finished state with its housing inverted.

Specifically, the process comprises the steps of firstly sorting a semi-finished product of the network filter with a plurality of magnetic rings, sorting and fixing the wire ends of enameled wires, then cutting the corresponding position of each sorted enameled wire end through a wire cutting mechanism 3, and forming a notch with the cutting depth not more than 45%;

and transferring the cut network filter semi-finished product to a winding mechanism 4, winding by using a winding head 12 positioned outside the pin, leading the enameled wire head into the end part of the inner side of the pin after the enameled wire head is lifted and a coil is formed on the winding head 12, and sending the enameled wire head to the next procedure after the winding is finished and the detection is qualified. Detecting the enameled wires with the notches after cutting, judging the enameled wires with the notch depth more than 45 percent as defect records and rejecting the enameled wires

Specifically, the process in this embodiment is implemented by using an automatic production line, as shown in fig. 1 to 13, and fig. 14 is a process flow chart for winding by using the production line. Fig. 1 and 2 show a structure diagram of the whole assembly line, and the assembly line sequentially includes a manual table 15, an inlet conveyor belt 1, a wire cutting mechanism 3, a wire winding mechanism 4, an outlet conveyor belt 5, and a manual table 15 from an output direction to an output direction.

The first manual table 15 is mainly used for placing and fixing the network filter semi-finished products on the corresponding jig 7, a plurality of network filter semi-finished products are fixed in the middle of a single jig 7, each semi-finished product is in a shell inverted fixing mode, and the back face of each semi-finished product is opened to expose a plurality of magnetic rings inside the semi-finished product. After the semi-finished products are fixed manually, the enameled wires in each semi-finished product are pulled out and fixed on the external wire clamps, so that two rows of enameled wire groups are formed on two sides of the jig 7.

And the second manual table 15 is mainly used for manually checking whether the wound product is qualified or not and checking the breaking condition of redundant thread ends.

Wherein, import transmission band 1 and export transmission band 5 are the same transmission structure for carry the tool 7 of network filter semi-manufactured goods and transport. And the transmission mechanism also comprises a chute 8 arranged on the wire cutting mechanism 3 and the wire winding mechanism 4, the jig 7 is limited to move only along the length direction of the jig by the chute 8, and temporary limitation is carried out by a limiting mechanism arranged at a corresponding position, so that the influence on the treatment process caused by instability of the jig 7 is avoided when the semi-finished product of the network filter on the corresponding jig 7 is treated.

In some embodiments, the thread cutting mechanism 3 includes a fixed end surface and a cutting module disposed on the fixed end surface, and the cutting module can move freely on the fixed end surface, including both manual and automatic control modes. And the network filters are placed on the fixed end face and are fixed and limited through the positioning mechanism. During cutting, the cutting die is moved to be close to the processed network filter, cutting is carried out according to requirements to form a notch with the cutting depth not more than 40% of the maximum diameter of the enameled wire, and the cutting mode comprises a single one-way cutting mode or a multiple reciprocating cutting mode.

In some embodiments, as shown in FIG. 3, a specific tangent line system is shown. The floor type operation table 2 is composed of a section bar frame, and pulleys are arranged at four corners of the bottom of the operation table 2 and are convenient to move. And the upper part is provided with a plurality of partition plates, and the partition plates on the horizontal plane are the fixed end surfaces in the above content.

The figure only shows the scheme that one sliding chute 8 is arranged on the operating platform 2, but a plurality of sliding chutes 8 can also be arranged on the operating platform 2, and each sliding chute 8 corresponds to one external conveying belt. At least one corresponding cutting module is arranged on the operating platform 2 for each sliding chute 8 and used for cutting the network filter entering each operating platform 2.

In some embodiments, the cutting module is a laser cutter 6, the laser cutter 6 is only illustrated in the figure as a single integrated module structure, but the laser cutter 6 comprises at least two lenses, namely a galvanometer and a field lens. The field lens is connected with an external laser generator, the vibrating mirror serves as a scanning module, scanning light beams can be emitted to scan a target object before laser is emitted, and laser beams are emitted by the field lens to perform cauterization and cutting after the position of the target is confirmed to be at a cutting position.

It should be noted that the laser cutter 6 burns the spot of the circular spot formed on the surface of the target by the converged beam, and is not used for cutting the enameled wire, but is originally used for burning the surface of the metal material to form a cutting groove or other structures. Since the incision is formed by photo-cautery, not by direct contact pressing or cutting, the position and state of the fixed enamel wire are not affected.

However, during cutting, the size of the formed light spot is generally larger than twice of the maximum outer diameter of the enameled wire, so that the width of the formed notch is larger, and the requirement can be met only by ensuring that the depth of the notch is less than 45%.

In some embodiments, the chute 8 is a fixed structure, and a belt or other conveying mechanism is arranged in the chute, so that the jigs 7 arranged in the chute 8 are conveyed, the jigs 7 are clamped by a positioning mechanism arranged on the operating table 2, and the positioning mechanism is opened for conveying after the cutting is finished.

In order to improve the flexibility of the apparatus, a moving frame is further provided outside the laser cutter 6, which is illustrated by only one L-shaped metal arm, i.e., a mechanism having at least two degrees of freedom of movement in the vertical direction, so that the laser cutter 6 can be spatially displaced with respect to the operation table 2, and the position thereof can be adjusted and fixed by an externally connected controller. When cutting, because the enameled wires on the single jig 7 are symmetrically arranged, the light beam emitted by the field lens can only move along a straight line. After the unilateral cutting is completed, the moving frame moves the unilateral cutting tool to the other side for continuous reverse displacement, so that the enameled wire cutting operation on the single jig 7 is completed.

In some embodiments, a special positioning mechanism is further disposed on the operation table 2, the positioning mechanism comprises a pneumatic rotating mechanism and a clamping plate, and the operation table 2 is provided with an air cylinder for supplying power. The pneumatic rotating mechanism drives the clamping plate to rotate, two ends of the clamping plate are respectively provided with an extending piece, and the distance between the two extending pieces is just right used for clamping a single jig or a plurality of jigs 7. In the figure, the outer walls of two sides of a single jig 7 in the length direction are just clamped, a matched positioning clamping groove can be arranged on the jig 7, and when the clamping plate rotates, the end part of the clamping piece is clamped and matched with the positioning clamping groove to realize limiting.

The distance between the plurality of jigs 7 in the sliding groove 8 is not limited, and the position of the jig can be limited only by the clamping plate of the positioning mechanism when the jig is cut.

Wherein, the mode that this embodiment utilized thread cutting mechanism 3 to carry out precutting line is: when one jig 7 moves to the corresponding area of the laser cutter 6, the detection sensor arranged on one side of the positioning mechanism detects the jig, and once the jig 7 reaches the designated position, the conveying is stopped. At this time, the positioning mechanism is controlled to rotate to clamp and limit the jig 7.

And then starting the laser cutter 6, scanning the enameled wire harness in the cutting area by a scanning galvanometer of the laser cutter 6, wherein the scanning beam is a wire harness arranged in a single group of enameled wires, and after all objects are determined to be in the cutting position, starting a laser generator of the laser cutter 6, and enabling the formed light spot to penetrate through the end part of one side of the corresponding cutting groove and fall on the surface of a laser contact area at the lower part of the cutting groove.

The spot is then moved along the length of the slot and toward the other side of the slot, during which the one-sided cutting is completed after a group of enamel wires have passed through their surfaces to form a cut of depth not greater than 45% of their diameter. Then, the moving frame is controlled to move to the other side of the jig 7, the enameled wire on the other side is cauterized and cut, and then the cutting operation of the single jig 7 is completed, so as to perform a reciprocating operation.

In some embodiments, when an enameled wire with at least a double-strand stranded wire structure is pre-cut, firstly determining the type of the enameled wire of the network filter processed in the same batch, and then obtaining enameled wire type data; the control system controls the light spot moving speed of the laser according to the enameled wire model data, and the speed reduction rate of the enameled wire is obtained by multiplying the twisted strand number by the coefficient of 1.5-1.8 when the enameled wire passes through the twisted wire structure.

In some embodiments, the winding mechanism 4 is optimally defined. The winding mechanism 4 is divided into a plurality of independent modules at two sides of a single sliding chute 8, each independent module can be independently controlled through an external control module, and winding processing is carried out on semi-finished products of the network filters on the jigs 7 transmitted in the sliding chutes 8.

As shown in fig. 5 and 6, each independent module includes a driving mechanism and a frame body, and a bobbin case 9 is provided outside the frame body. And be provided with a plurality of winding heads 12 on the support body, winding head 12 includes guide head 13 and anchor clamps 14, and every anchor clamps 14 all can be with being fixed the enameled wire of 7 on the tool cramp and rotate around guide head 13 for the enameled wire by the cramp is coiled on guide head 13.

Due to the fact that the winding heads 12 are arranged, the distance between every two winding heads 12 can be adjusted, and when one of the guiding heads 13 is aligned with any pin, the guiding heads 13 of the other winding heads 12 can be aligned with one pin. Each guide head 13 is initially aligned by the drive mechanism with the pins of the network filter on the same or several jigs 7 and the winding operation is then started.

Preferably, the driving mechanism has a single-axis moving frame, i.e., the winding translation frame 10. The winding translation frame 10 comprises a frame body with a certain length and a screw rod arranged in the frame body, wherein a motor is arranged at one end of the frame body to drive the screw rod to rotate.

The frame body is provided with a sliding table which can linearly reciprocate along the length direction of the frame body, the sliding table is provided with a ball nut matched with the lead screw, the sliding table is controlled to move by rotating the motor, and the motor is connected with an external control module.

The single-shaft moving frame is fixed on a fixed end face, and a fixed end part is also arranged on the fixed end face and is loaded with a plurality of network filters. Or the frame body of the single-shaft moving frame is provided with an extending end part, and the jig 7 is fixed on the extending end part. At this time, the placing direction of the plurality of network filters on the jig 7 is parallel to the moving direction of the sliding table, and only a proper distance is required to be set so that the distance between the end of the guide head 13 of the winding head 12 and the pins can meet the process requirements.

It should be noted that the screw transmission system is a common movement control system, but the present embodiment is not limited thereto, and transmission systems such as gears, pneumatic, hydraulic, and electromagnetic may also be adopted. It should be noted that the jig 14 and the guide head 13 in the above embodiment are operated in synchronization, but since the winding head 12 in this embodiment can only move in the direction parallel to the jig 7, the lateral movement of the yarn clamping is inevitably blocked and cannot be realized. The end of the fixture 14 in this solution can move by itself, and when the winding head 12 reaches the corresponding pin, the end of the fixture 14 in the initial position does not contact the enameled wire fixed on the fixture 7. Then, the end of the clamper 14 automatically moves downward and clamps the enamel wire and then lifts up, and then the winding is started.

Alternatively, as shown in fig. 5, the driving mechanism has two single-axis moving frames, and the single-axis moving frame controls the movement of the slide table provided therein by using a screw transmission method as in the above-described embodiment. The difference lies in that tool 7 and wire winding module set up respectively on the slip table of difference, then can carry out the ascending mobility control of two at least directions. The sliding table provided with the jig 7 can move along the placing direction of the network filter, and the winding module can move along the direction perpendicular to the surface of the jig 7. In the scheme, the winding module is controlled by the single-shaft moving frame to move towards the jig 7, and the end part of the guide head 13 is close to the corresponding pin and the distance between the guide head and the pin is controlled within a required range to perform winding. When the winding is completed, the winding module is moved upward to a position so that the jig 14 can be moved laterally without being blocked by the enamel wire. Then the jig 7 is moved again so that the end of the guide head 13 can be aligned with another pin for winding.

Alternatively, there are two single-axis moving frames connected to each other, i.e., the winding translation frame 10 and the winding lifting frame 11. That is, the frame body of one single-shaft fixing frame is fixed on the sliding table of the other single-shaft fixing frame, and any one of the jig 7 or the winding module is fixed on the other sliding table. If the wire winding module sets up on the slip table that can move, then can enough follow tool 7's network filter and put the direction sideslip, also can whole vertical migration simultaneously, can accomplish automatic displacement wire winding equally.

In some embodiments, the structure of the single winding head 12 is optimized, as shown in fig. 8 and 9, and it can be seen that the winding head 12 includes a rod-shaped bushing rotatably connected to the hole of the winding translational frame 10 by a bearing or the like. A runner is provided at the end of the liner, and a ring metal member is fitted over the liner, which is the end structure for the clamp 14.

The lower end of the bushing is provided with a telescopic guide head 13, and the clamp 14 is of a pneumatic structure, so that the whole winding translation frame 10 integrally moves downwards in use and stops after the end of the guide head 13 abuts against the end of the corresponding pin. At this time, since the clamping arms themselves at the end of the clamp 14 are arranged lower, the end of the clamp 14 can already clamp the enameled wire on the jig 7.

Because the guide head 13 is the extending structure, then the accessible control wire winding crane 11 makes it can also continue downstream after leaning on with the pin, and guide head 13 atress inwards shrinks this moment, and anchor clamps 14 live enameled fixture 14 also. And then moving the winding crane 11 again to enable the clamp 14 to lift the enameled wire upwards, wherein the guide head 13 extends out completely due to external force of the guide head, and the conical cambered surface at the end part of the guide head can guide the enameled wire on the clamp 14 to be attached and fall downwards in the winding process. When the clamp 14 acts around the guide head 13, the enameled wire can be attached to the tapered arc surface of the guide head 13 and guided downwards into the lead due to its gravity or the downward movement of the clamp 14, thereby completing the winding process.

After the winding operation of a single pin is completed, the whole winding translation frame 10 is moved upwards for a certain distance, then the winding translation frame 10 is moved to enable the guide head 13 to be aligned with the adjacent pin, and then the winding translation frame 10 falls down again to repeat the operation.

After the single-side pins of the network filter have finished the winding operation, the jig 7 is moved inwards by the direct moving device, and the guide head 13 restored to the initial position is aligned with the pins of the network filter on the other side for winding.

After the jig 7 or the network filters on the same batch of fixed jigs 7 complete the winding of the pins, the limiting mechanism is opened at the moment, the transmission structure in the chute 8 moves the jig 7 backwards, and simultaneously the jig 7 which is newly loaded with the network filters without winding the pins on the other side is moved to the corresponding position to repeat the operation.

It is worth explaining that, in the actual production process, because have a plurality of tools 7 that the interval equals in through spout 8, then in order to improve wire winding efficiency, can set up a plurality of wire winding mechanisms 4 and tangent line mechanism 3 in single spout 8 both sides, carry out wire winding and tangent line simultaneously to a plurality of tools 7 of certain length and handle. And be equipped with a plurality of pneumatic control's stop gear on the operation panel 2, lock simultaneously and open, the tool 7 after accomplishing a set of tangent line can directly be transported to in the mechanism 4 of winding and carry out single batch wire winding.

In some embodiments, the control module is disposed on the console 2, and the control module is fixed on the console 2 by a vertical rod and has a display screen and switch control buttons. The control module is connected with a master control device through a cable, the master control device monitors the running of all devices, and system parameters are debugged and set before production, so that the control module can automatically perform winding according to a preset program.

In some embodiments, a visual inspection device may be further integrated on the console 2, that is, a camera is used to continuously collect information, a control module or other terminal device is used to perform image recognition calculation, and a pin position is detected. And recording the abnormal information once the abnormal information is found, determining the serial number of each network filter, and then removing the serial number in the subsequent processing process.

Wherein, look and examine equipment and include at least three independent structure, look including setting up the first appearance of examining on reason line platform, set up the second on tangent line mechanism 3 and look the appearance and set up the third on winding mechanism 4 and look the appearance. Wherein, the appearance is examined to second sight on tangent line mechanism 3 is equipped with two, sets up respectively in feeding department and ejection of compact department for detect the material before the tangent line and behind the tangent line. The placement of the network filter and the fixed position of the wire harness are checked before cutting, and once unqualified products are found, an operator is immediately indicated to handle the unqualified products. And the depth of cut is checked through a visual inspection instrument after cutting, so that the unqualified products are removed, meanwhile, the depth of cut of each batch of products can be counted, and more production data are acquired as feedback basis and debugging reference.

In some embodiments, as shown in fig. 10 to 13, the end of the guiding head 13 has a tapered arc surface, i.e. a tapered transition section, and the enameled wire is wound on the tapered transition section, so that the enameled wire can fall down along the direction of reducing the diameter of the cross section of the tapered transition section under the influence of an external force or self gravity, and thus fall on the pin. The end of the guiding head 13 is also provided with a socket 13.1, the size of the socket 13.1 is slightly larger than the size of the inner end of the pin, and when the guiding head 13 is abutted against the inner end of the pin, the inner end of the pin is just inserted into the socket 13.1 to realize better connection and fixation effect.

However, in the winding process, the coil formed on the tapered transition section needs to be led into the lead, so that the smooth falling process is a core point of the process. The conical transition section is defined by the slope of the outer side edge of the section after transverse cutting along the axial direction, at least the transition section with constant slope of the section is a standard conical transition shape, and the inclination angle of the transition section ranges from 10 degrees to 60 degrees, wherein the angle refers to the included angle between the outer side edge and the axial direction. As shown in fig. 12, three tapered transition sections are provided on the guide head 13, wherein h1 and h2 are provided to facilitate the flatness and continuity of the transition section, and to form a tapered transition section structure with a smaller cross-sectional radius at the lowest h3 part while ensuring the structural strength.

Preferably, the outer side edge of the tapered transition section has an inclination in the range of 15-35 °, more preferably in the range of 25-32 °. In order to verify and obtain the optimal inclination angle range and the optimal angle, the guide head 13 is fixed on the upper part of any pin of the network filter, then the same clamp 14 is adopted to start the enamelled clamp 14 with the same specification and wind the enamelled clamp for three circles, then the enamelled clamp is tested in two modes of autonomous falling and guided falling respectively, and then the result and the yield are checked. Wherein, only the inclination angle of the third conical transition section and trial production of a plurality of samples are tested, the inclination angle of the tested sample of the guide head 13 comprises a straight rod control group without the inclination angle and a total of 16 experimental groups which are continuously increased to 80 degrees by an angle difference of 5 degrees, and each experimental group tests 200 windings.

And then judging the yield and the winding completion time of each experimental group. First, it was determined that the yield of the experimental groups below 5 ° and 65 ° and above was below 50%, especially with the autonomous drop process, more than 80% of the coils could not fall completely onto the pins in samples with an angle less than 5 °. Then, the preferred angle range is determined within the range of 5-65 deg.. Wherein, the yield of the experimental group within the range of 15-35 degrees is higher than 90%, and the autonomous falling rate is higher than 90%. While the yield in the 25 and 30 ° experimental groups was higher than 98% and both were able to fall off autonomously. Then, an additional experiment was performed for an upper limit of 30 °, and an optimal upper limit range was determined to be 32 °.

Then, the average winding time of the experimental group of the guide heads 13 with the inclination angle of 10 ° or less is lower than the process requirement, and the minimum process standard can not be achieved. When the angle is less than 25 degrees, the self-dropping rate of the coil is below 95%, and the coil cannot automatically drop in the test sample. The optimal angle range is determined to be between 25-32 deg. in order to ensure the winding success rate of the coil as much as possible.

It is worth noting that the yield rate includes the detection of the wire winding condition and the product test, and even if the foot winding process is finished in the appearance inspection of some products, the enameled wire is damaged to influence the service performance, and the enameled wire cannot be calculated as a qualified product.

Meanwhile, due to the fact that the wire cutting mechanism 3 is arranged in the system, not only can the coil formed on the guide head 13 be smoothly dropped on the pin, but also the dropped coil can be automatically disconnected at the corresponding position, and therefore redundant wire ends can be automatically removed.

Since this solution is only suitable for processes and equipment with external guide heads 13, the size of the cut made by pre-cutting in other manual or automatic winding equipment is liable to cause the problem of unsuccessful winding, further affecting the yield. In order to further determine the influence of the cutting on the yield of the external winding and the disconnection effect after winding, the embodiment tests the external winding and the disconnection effect after winding, so as to obtain the optimal cutting conditions and other parameters, and further obtain the optimal implementation effect.

The notch depth is to ensure that the enameled wire can be naturally broken or easily broken after the winding is completed, and the breaking process does not have adverse effect on the wound coil structure.

The adverse effect means that the wound coil is detected whether to reach the standard or not through visual inspection equipment after the coil is subjected to a wire end removing process, and if not, the adverse effect is judged; meanwhile, the formed network filter is subjected to a power-on test, and if the product cannot pass the test, the adverse effect is determined under the condition of a limited condition test.

It should be noted that if the depth of the cut is large, the thread end is easily broken during subsequent winding and even transferring. Although the position of the notch is generally a certain length outside the coil in order to ensure the stability of the coil, the holding fixing point of the clamp 14 is far away from the position of the notch during the winding process, and once the coil is broken before forming, the subsequent winding operation cannot be completed through the clamp 14.

However, since the prior art does not have a process of cutting the line first, only the maximum cutting depth is defined, and then the cutting range is preferably narrowed by experiments.

The testing process is as follows, the wire cutting system and the process are utilized to manufacture a sample, the pin of the network filter is of a square head structure, the maximum cross-sectional dimension of an enameled wire adopted by the pin is 0.26mm, the diameter of a conductor is 0.23, and the minimum thickness of a paint film is about 0.017.

The network filter further comprises double stranded wires, and each network filter is provided with about 40% of double stranded enameled wires.

The laser cutter 6 used is a conventional 80 or 100w laser marking machine device, which is adapted by being fixed on a table top by customization and software programming.

The power and spot size of the laser cutter 6 are first adjusted to maintain a constant power output while maintaining the consistent spot size formed on the enameled wire. Detection by visual inspection equipment confirmed that nine groups of sample groups were formed after cutting, with approximately 2%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70% of the cut depth being grouped. Set up two contrast groups simultaneously, a set of sample that obtains through the mode of current later stage rupture detects, and another group is the sample of direct coiling enameled wire on the pin. With a single network filter as a single sample, the number of samples per group was 80.

It should be noted that the cut depth is defined as an average cut depth determined by a computer according to information in an image after the image is picked up or photographed by the visual inspection equipment. Because the wire rod is thin, the end face formed after laser burning is not a standard section, and the judgment error is about 2 percent generally.

The detection items are respectively the coil winding yield, the transfer wire breakage rate, the natural wire breakage rate after winding (the wire breakage rate under the action of no external force after the coil winding is finished) and the power-on detection qualification rate of the wound finished product as reference indexes.

The results are as follows:

	2%	5%	10%	20%	30%	40%	50%	60%	70%
										coil yield (%)	100	100	100	95	93.8	93.8	81.3	56.3	17.5
Percentage of transfer line breakage (%)	0	0	0	0	0	3.8	7.5	11.3	11.3
										Natural percentage of broken line (%)	8.8	17.5	47.5	86.3	95	100	100	100	100
Test pass percentage (%)	86.3	88.8	97.5	100	100	93.8	81.3	56.3	15

As can be seen in the figure, when the depth of the cut is more than 40%, the forming rate of the coil is already lower than 90%, the process requirement is not met, meanwhile, the coil yield is not only lower than the forming rate of the coil, but also the formed coil is looser due to the excessive burning influence.

The notch depth is lower than 10% of the sample, the natural wire breakage rate is low, the coil formation is influenced in the pulling process, and the wire is damaged due to abrasion when the pin is in the square-notch structure during the testing, so that the yield is influenced.

As can be seen from the data, when the cutting depth is more than 20%, the natural wire breakage rate is high, and meets the process requirements, so the optimal range is selected to be 20% -40%.

It is also worth noting that the natural breakage rate here is completely without any assistance of human or equipment, and the breakage is checked immediately after the clamp 14 is released after the winding is completed. However, generally, when the cut is deeper than 10%, the jig 14 is directly moved to pull the enameled wire, and the excess end of the enameled wire can be directly disconnected from the cut without destructively affecting the forming quality of the coil. Only the natural break can be more in line with the process requirements and since the coil is wound on the external winding head 12, the natural break can fall directly onto the pin under its own weight.

Meanwhile, in order to verify the cutting conditions of the double-strand or multi-strand enameled wires, experimental conditions with different rate increases are independently set for testing, and the test is mainly carried out on the double-strand enameled wires. In the actual production process, the direction of the tangent plane of the double-strand enameled wire cannot be determined when the double-strand enameled wire is cut off, so that a notch is formed on a single wire during burning, and the other independent wire cannot be directly torn off during winding. Therefore, the same wire breakage effect as that of the single wire can be maintained by extending the burn time to ensure a proper cut depth. Tests show that when the passing time is increased to 1.5-1.8 times, the wire breakage effect can keep the same wire breakage rate as that of a single-stranded wire, once the time is increased, the situation that the effective coil cannot be formed due to large cutting depth is easily caused, and the effective cutting depth cannot be obtained due to time reduction.

The present invention is not limited to the above-described alternative embodiments, and various other forms of products can be obtained by anyone in light of the present invention. The above detailed description should not be taken as limiting the scope of the invention, which is defined in the claims, and which the description is intended to be interpreted accordingly.

Claims

1. A winding pin manufacturing process of a network filter is used for winding an enameled wire end of an inner magnetic ring of the network filter at the end part of the inner side of a pin, and is characterized in that: firstly, arranging a semi-finished product of the network filter with a plurality of magnetic rings, arranging and fixing the wire ends of the enameled wires, then cutting the corresponding position of each arranged enameled wire end through a wire cutting mechanism (3) and forming a notch with the notch depth being more than or equal to 10% and less than 30%;

2. The winding pin manufacturing process of the network filter according to claim 1, wherein: before cutting, the semi-finished product of the network filter is fixed on a jig (7), the enameled wire ends are manually arranged out and fixed on a wire clamp of the jig (7), and a plurality of enameled wire ends are formed on the jig (7) side by side.

3. The winding pin manufacturing process of the network filter according to claim 1, wherein: and detecting the enameled wires with the notches after cutting, and judging the enameled wires with the notch depth range of 10-30% as the defect records and rejecting the enameled wires.

4. A winding process of a network filter according to claim 3, characterized in that: and after winding, detecting the forming condition and the wire breaking condition of the coil, and feeding back and adjusting the cutting depth according to the detection result.

5. The winding pin manufacturing process of the network filter according to claim 1, wherein: the winding head comprises a guide head (13) and a clamp (14), the end of the enameled wire is clamped by the clamp (14) and wound around the guide head (13) for at least one circle to form a coil, and the coil is disconnected from a notch after being formed and is separated from the clamp to be led into the end part of the inner side of the pin downwards.

6. A winding pin manufacturing process of a network filter according to claim 5, characterized in that: during winding, the corresponding enameled wire is clamped by the clamp (14) and then lifted upwards, and after the enameled wire is rotated around the guide head (13) to form a coil, the enameled wire is guided onto the pin by the gravity of the coil or by the traction of the clamp (14) to move downwards, and is disconnected from a tangent line in the falling process.

7. A winding pin manufacturing process of a network filter according to claim 5, characterized in that: the guide head is provided with a conical section with the cross section size continuously reduced towards the falling direction and a smooth surface, and the enameled wire is wound on the surface of the conical section.

8. A winding pin manufacturing process of a network filter according to claim 5, characterized in that: the process is completed by programmable automatic equipment, and a plurality of network filters are fixed on the same jig for simultaneous winding.

9. A winding pin manufacturing process of a network filter according to claim 5, characterized in that: the winding head is of a telescopic structure, supports against the end part of the corresponding pin when the pin is wound, enables the clamp on one side to move downwards and clamp the enameled wire fixed on the jig through pressing and shrinking once, and performs secondary pressing to guide the coil into the pin after the clamp lifts and winds the wire.