CN115954205A - Electromagnet winding process method and device - Google Patents

Abstract

The invention relates to the technical field of electromagnets, in particular to an electromagnet winding process method and an electromagnet winding device, wherein the electromagnet winding device comprises a rack and a tensioner frame; the wire winding machine is characterized in that a large bottom plate is arranged at the top of the rack, a tail jacking mechanism, a spindle box, a winding motor and a wire arranging mechanism are correspondingly arranged on the large bottom plate, the tail jacking mechanism and the spindle box are oppositely arranged, the winding motor is connected with the spindle box, a wire feeding mechanism is slidably mounted on the wire arranging mechanism, and a winding length detection mechanism is fixedly mounted on the wire feeding mechanism; the upper end of the tensioner frame is fixedly provided with a servo motor active wire feeding tensioner, and the bottom of the tensioner frame is provided with an enameled wire. The invention has the characteristics of simple operation, convenient use and maintenance, high servo control precision, strong practicability, safety, reliability and the like; the electromagnetic force of the original design state of the electromagnet coil can be effectively recovered, the use quality is stable, and the scrapped electromagnet can be reused by 100 percent.

Description

Electromagnet winding process method and device

Technical Field

The invention relates to the technical field of electromagnets, in particular to an electromagnet winding process method and device.

Background

The electromagnet is used in an aircraft electromagnetic valve and comprises a push rod, a framework, a stop block, an armature and a coil, wherein the coil is formed by winding an enameled wire in the framework as shown in figure 1, the push rod is made of a non-magnetic material (such as copper), the framework, the stop block and the armature are generally made of a soft magnetic material (electrical pure iron DT 4A), the coercive force is small, the magnetization is easy, the stop block is fixedly installed, and the armature can flexibly move in an inner cavity of the framework under the action of a magnetic field. The stop block and the armature can be magnetized rapidly under the action of a magnetic field generated by coil current, the stop block and the armature are magnetized into a magnetic field unit, and the magnetic pole sequence is as follows according to the structure sequence: n, a stop block S; n armature S. The magnetic field characteristics are opposite and opposite, the armature iron is attracted to the stop block, and the ejector rod is pushed to open the front end valve for working. The current direction is opposite, and the magnetic pole sequence is opposite: s, a stop block N; s, the armature N is opposite in magnetic pole direction but opposite in attraction, and the armature is attracted to the stop block to push the ejector rod to open the front end valve. It appears that the electromagnetic thrust direction is unchanged. Therefore, the winding direction (left-handed or right-handed) of the electromagnet is not affected. Under the condition that an electromagnet coil is powered off, a current magnetic field disappears, a magnetic field of a soft magnetic material (small coercive force and small residual magnetism) almost disappears, electromagnetic force between a stop block and an armature disappears, and the initial position of the armature is recovered under the action of a front-end valve spring.

In the process of long-term use, decomposition and repair of the electromagnet, faults such as damaged enameled wires, unqualified electromagnet performance and the like can not be used continuously due to corrosion and non-insulation, so that the electromagnet is scrapped. Therefore, the device and the method capable of repairing the electromagnet are designed, and have important significance in the maintenance operation of the electromagnet.

However, the decomposition of the existing original electromagnet can find that in order to make room to ensure that the enameled wires and the lead-out wire connectors are embedded into the coil, the number of turns wound on each layer of the coil is different, the layers are not clear and regular, the enameled wires on two ends are relatively disordered and have fewer turns, and the number of turns in the middle is more and is relatively regularly arranged; and further decomposition can find that the number of turns of the coils at two ends of each layer is not reduced in an arithmetic progression, but is staggered with each other, and obviously presents a manual winding characteristic.

Therefore, how to ensure that the welding joint of the enameled wire and the lead-out wire can be successfully embedded into the coil, and how to eliminate the wire jumping and sparseness caused by accumulated errors of the wire diameter of the enameled wire in the winding process can also ensure that the winding displacement of the coil is neat and not loose; how to control the tension of the enameled wire; the problems of how to express the servo relationship between the wire feeding function and the main shaft driving the framework to rotate and wind the wire and the like exist, and the difficulty is high.

Disclosure of Invention

In order to solve the technical problem, the invention provides an electromagnet winding process method and device. The original design state of the coil is recovered by rewinding the original electromagnet framework and the coil is continuously used, the maintenance quality of the airplane electromagnet and the utilization rate of spare parts are improved, and the method has important significance in electromagnet maintenance operation.

The technical problem to be solved by the invention is realized by adopting the following technical scheme:

an electromagnet winding device comprises a frame and a tensioner frame;

the wire winding machine is characterized in that a large bottom plate is arranged at the top of the rack, a tail jacking mechanism, a spindle box, a wire winding motor and a wire arranging mechanism are correspondingly arranged on the large bottom plate, the tail jacking mechanism and the spindle box are oppositely arranged, the wire winding motor is connected with the spindle box, a wire feeding mechanism is slidably mounted on the wire arranging mechanism, a wire winding length detection mechanism is fixedly mounted on the wire feeding mechanism, and the wire arranging mechanism is located at the side position between the tail jacking mechanism and the spindle box;

the upper end part of the tensioner frame is fixedly provided with a servo motor active wire feeding tensioner, and the bottom of the tensioner frame is provided with an enameled wire;

the enameled wire is followed servo motor initiatively sends out the process the wire winding length detection mechanism carries out the enameled wire length calculation back, through send line mechanism, winding displacement mechanism to carry out X direction and Y direction wire winding direction, and the cooperation the tail top mechanism with headstock clamping electromagnetism iron skeleton and drive the electromagnetism iron skeleton and rotate in order to realize the electro-magnet wire winding.

Preferably, the tail top mechanism comprises a slide rail fixedly mounted on the large bottom plate, a slide block slidably mounted on the slide rail, a cylinder support arranged on the slide block, and an air source support, wherein an air cylinder is mounted on the cylinder support, the air cylinder is connected with a top, an air source stabilizer is mounted on the air source support, a locking mechanism is arranged on the slide block, and the output air pressure of the air source stabilizer is 0.5-0.6 MPa.

Preferably, a spindle connected with the winding motor is arranged inside the spindle box, the spindle is connected with a rotating shaft in a detachable connection mode, and a touch screen is mounted outside the spindle box.

Preferably, the winding motor comprises a winding motor mounting frame fixedly mounted on the large base plate, a spindle servo motor mounted on the winding motor mounting frame, and a rotation speed sensor connected with the spindle servo motor, and the spindle servo motor is connected with a spindle in the spindle box through a gear.

Preferably, the wire winding length detection mechanism comprises a length detection mounting plate fixedly mounted on the wire feeding mechanism, and an encoder, three wire arrangement wheels, two wire passing wheels, an encoder driving wheel, a wire pressing synchronous belt and three synchronous belt wheels arranged on the length detection mounting plate, wherein the encoder is connected with the encoder driving wheel, and the wire pressing synchronous belt is connected with the encoder driving wheel and the three synchronous belt wheels.

Preferably, the wire feeding mechanism comprises a wire feeding precise linear module arranged on the wire arranging mechanism, a wire feeding servo motor connected with the wire feeding precise linear module through a coupler, a wire feeding mounting plate connected with the wire feeding precise linear module, and an adjustable wire arranging wheel connected to the wire feeding mounting plate, and the wire winding length detection mechanism is connected to the wire feeding mounting plate.

Preferably, the winding displacement mechanism comprises a mounting seat fixedly mounted on the large bottom plate, a winding displacement precise linear module fixedly mounted on the mounting seat, and a winding displacement servo motor connected with the winding displacement precise linear module through a coupler, and the winding displacement precise linear module is mounted on the winding displacement precise linear module through a connecting plate.

Preferably, the type of the servo motor active wire feeding tensioner is SF600, and the tension range is 20-450g.

An electromagnet winding process method applies an electromagnet winding device and comprises the following specific steps:

selecting a corresponding matched rotating shaft according to the type of the electromagnet framework, inserting the rotating shaft into a main shaft hole, screwing the rotating shaft through a locking screw, and clamping the electromagnet framework through the rotating shaft and a tail jacking mechanism;

secondly, placing an enameled wire coil at the bottom of a tensioner frame, leading a wire drawing head into a winding length detection mechanism after passing through a wire feeding wheel of a servo motor active wire feeding tensioner, passing through two wire passing wheels, passing between an encoder driving wheel and a synchronous belt wheel, passing out of the two wire passing wheels, sequentially passing through three wire arranging wheels, sequentially passing a wire head through an adjustable wire arranging wheel on the wire feeding mechanism and a wire arranging needle nozzle in the adjustable wire arranging wheel, placing the enameled wire into a lead-out wire groove on an electromagnet framework to be slightly tensioned, winding the head of the enameled wire on a rotating shaft locking screw for one circle, bonding the head of the wire on the rotating shaft by using paper adhesive tape to prevent loosening, rotating the rotating shaft for one circle, and uniformly attaching the enameled wire to the end part;

in the winding process of the step (III), a winding length detection mechanism detects the winding length of the enameled wire, a touch screen on a spindle box calculates the resistance of a coil and displays a numerical value, and whether the resistance of the coil of the electromagnet meets the technical index requirement is judged;

in the winding process of the step (four), when one layer is wound, the wire arranging needle nozzle in the adjustable wire arranging wheel automatically retreats for a wire diameter distance along the Y direction, and when the main shaft rotates for one circle, the wire arranging needle nozzle in the adjustable wire arranging wheel automatically moves for a wire diameter distance along the X direction under the driving of the wire arranging mechanism;

step (five), errors are generated when the wire arranging mechanism moves along the X direction, and the accumulated moving errors exceed the diameter distance of three turns and are processed in time;

and step six, repeating the step four to the step five until the set winding number is finished.

Preferably, the specific processing procedure of the accumulated moving error of the traverse mechanism in the step (five) is as follows: the method comprises the steps of firstly pressing a start/stop key in a touch screen on a main shaft box to pause winding, then pressing a "←" key or a "→" key in the touch screen on the main shaft box to change the position of a winding displacement mechanism, simultaneously adopting a piecewise fitting method to carry out nonlinear expression on the relation between input quantity and output quantity stepping motors of a main shaft motor rotating for one circle, setting parameters in layers according to the enameled wire state on the layer number, enabling the winding displacement mechanism and the main shaft to move synchronously, and eliminating the movement accumulated error of the winding displacement mechanism.

The invention has the beneficial effects that:

the winding device eliminates the movement accumulated error of the winding mechanism by adopting a sectional fitting mode, and has the characteristics of simple operation, convenient use and maintenance, high servo control precision, strong practicability, safety, reliability and the like; the winding method can effectively recover the electromagnetic force of the electromagnet coil in the original design state, has stable use quality, enables the scrapped electromagnet to be reused by 100 percent, improves the maintenance quality of the airplane electromagnet and the utilization rate of spare parts, has wide application prospect, and has remarkable military, economic and social benefits.

Drawings

The invention is further illustrated with reference to the following figures and examples:

FIG. 1 is a schematic diagram of a conventional electromagnet;

FIG. 2 is a schematic view of the overall structure of the present embodiment;

fig. 3 is a schematic structural view of the tail jack mechanism in the present embodiment;

FIG. 4 is a schematic view of the connection between the winding motor and the spindle head in this embodiment;

FIG. 5 is a first schematic structural diagram of a winding length detecting mechanism according to the present embodiment;

fig. 6 is a second schematic structural view of the winding length detection mechanism in the present embodiment;

FIG. 7 is a first schematic view illustrating a connection relationship among the winding length detecting mechanism, the feeding mechanism and the winding displacement mechanism in the present embodiment;

FIG. 8 is a second schematic view showing the connection relationship among the winding length detecting mechanism, the feeding mechanism and the winding displacement mechanism in this embodiment;

FIG. 9 is a schematic view of the connection between the active wire feeding tensioner of the servo motor and the tensioner frame in this embodiment;

fig. 10 is a schematic diagram illustrating a routing path of the enameled wire in the winding length detection mechanism according to the present embodiment;

FIG. 11 is a schematic view showing the height adjustment of a wire arranging needle nozzle in the adjustable wire arranging wheel of the wire feeding mechanism in this embodiment;

fig. 12 is a schematic structural view of the electromagnet skeleton in this embodiment.

In the figure: 1. a frame; 2. a tail ejection mechanism; 201. a slider; 202. a locking mechanism; 203. a slide rail; 204. a cylinder support; 205. a tip; 206. a cylinder; 207. an air source stabilizer; 208. a gas source support; 3. a large base plate; 4. a main spindle box; 5. a winding motor; 6. a winding length detection mechanism; 601. an encoder; 602. a length detection mounting plate; 603. a wire arrangement wheel; 604. a wire passing wheel; 605. an encoder transmission wheel; 606. pressing a synchronous belt; 607. a synchronous pulley; 7. a wire feeding mechanism; 701. a wire feeding precision linear module; 702. a wire feeding servo motor; 703. a wire feeding mounting plate; 704. an adjustable wire arrangement wheel; 8. a wire arranging mechanism; 801. a mounting seat; 802. a flat cable precise linear module; 803. a flat cable servo motor; 9. a servo motor actively sends a wire tensioner; 10. a tensioner frame.

Detailed Description

In order to make the technical means, the creation characteristics, the achievement purposes and the effects of the invention easy to understand, the invention is further explained in the following by combining the attached drawings and the embodiments.

As shown in fig. 2, an electromagnet winding device includes a frame 1, a tail-top mechanism 2, a large bottom plate 3, a main spindle box 4, a winding motor 5, a winding length detection mechanism 6, a wire feeding mechanism 7, a wire arranging mechanism 8, a servo motor active wire feeding tensioner 9, a tensioner frame 10, and related accessories (power wires, fuses, sockets, fixing screws, etc.).

The large bottom plate 3 is fixedly arranged at the top of the rack 1, the tail jacking mechanism 2, the spindle box 4, the winding motor 5 and the wire arranging mechanism 8 are correspondingly and fixedly arranged on the large bottom plate 3, the tail jacking mechanism 2 and the spindle box 4 are oppositely arranged, the winding motor 5 is connected with the spindle box 4, the winding length detection mechanism 6 is arranged on the wire feeding mechanism 7, and the wire feeding mechanism 7 is slidably arranged on the wire arranging mechanism 8; the wire arranging mechanism 8 is positioned at the rear side edge position between the tail jacking mechanism 2 and the spindle box 4; the tensioner frame 10 is positioned at the rear side of the rack 1, and the servo motor active wire feeding tensioner 9 is installed at the top of the tensioner frame 10.

Further, frame 1 contains the rack, by steel sheet preparation + spraying plastics processing, the overall dimension is: 1000mm (length) x 700mm (width) x 800mm (height), weight: 300KG. The interior of the cabinet is divided into two parts by an electrical insulating plywood, one part (divided into three layers) can be used for storing tools, clamps, necessary technical data and random accessories, and the other part is used for installing a circuit board, a cable bridge and the like after three-proofing treatment (wet, mildew and bacteria).

Further, as shown in fig. 3, the tail-top mechanism 2 is composed of a sliding block 201, a locking mechanism 202, a sliding rail 203, a cylinder bracket 204, a top 205, a cylinder 206, an air source stabilizer 207, an air source bracket 208 and correspondingly connected fixing screws.

The dimensions of the slide rail 203 are: the locking mechanism is characterized in that the locking mechanism is 450mm (long) × 100mm (wide) × 20mm (high), the locking mechanism is made of a stainless steel plate, an inverted T-shaped groove is formed in the middle of the inner side of the sliding rail 203 and is 20mm away from the edge, the width of the groove surface is 20mm, the length of the groove surface is 350mm, two inverted T-shaped bolts (composed of studs with threads at two ends and square blocks with screw holes in the middle) used for installing the locking mechanism 202 are arranged, the studs and the square blocks are made of stainless steel, the inverted T-shaped bolts penetrate through the two holes of the sliding block 201 and then two handles (the handle holes are in the shape of a ' T ' and are matched with the ' shaped threaded columns at the upper ends of the bolts) and are fixedly screwed through screws and gaskets. Thus, the slider 201 can be locked by rotating the handle clockwise, the slider 201 can be loosened by rotating the handle anticlockwise, and the slider 201 can freely slide on the sliding rail 203.

The dimensions of the slider 201 are: 180mm (long) × 150mm (wide) × 100mm (high), which is made of stainless steel bars (hollow in the middle, light in weight), the lower part is concave and is in precise clearance fit with the slide rail 203, the upper part is used for mounting the air cylinder bracket 204 and the air source bracket 208, the air cylinder 206 is mounted on the air cylinder bracket 204, and the air source stabilizer 207 is mounted on the air source bracket 208 and is fixed and screwed by screws. The cylinder support 204 and the air source support 208 are made of stainless steel plates, and the cylinder 206 and the air source stabilizer 207 are finished parts (selected from AIRTAC or the like).

The center 205 is arranged on the left side of the cylinder 206, on one hand, the center can be rigidly and integrally propped against the electromagnet framework under certain air pressure, and on the other hand, the center 205 is not in contact with the inner wall of the cylinder 206 under the action of air suspension, so that the abrasion can be reduced when the center rotates along with the electromagnet framework installation main shaft, and the coaxial rotation is ensured without swinging. The gas source stabilizer 207 can stably output 0.5-0.6 MPa of gas pressure.

The large bottom plate 3 is made of a stainless steel plate, and the size of the large bottom plate 3 is as follows: 920mm (length) × 650mm (width) × 25mm (height). Is fixedly arranged on the frame 1 through screws.

Further, as shown in fig. 4, the headstock 4 is a stainless steel plate welded component, and the size of the headstock 4 is as follows: 250mm (length) × 300mm (width) × 310mm (height), and a touch screen and control buttons are mounted on a panel outside the headstock 4. And a main shaft support (a high-precision bearing is arranged in the support) are arranged in the main shaft box 4. The rotating shaft, the stop pin and the top cover are matched and processed according to the corresponding sizes of the winding frameworks of electromagnets of different models (magnetic materials are processed and can be adsorbed on the winding frameworks). The rotating shaft is screwed by the locking screw after being inserted into the spindle hole. See fig. 3. The main shaft is driven by a winding motor, the rotating speed of the main shaft is 0-500 rpm (depending on the diameter of the wire), and a rotating speed sensor is arranged for measurement and control. The winding diameter range is 0.1-1.0 mm.

Further, the winding motor 5 is composed of a mounting rack, a spindle servo motor and a rotation speed sensor, wherein the mounting rack is formed by numerical control machining of a stainless steel plate according to the mounting sizes of the spindle servo motor and the rotation speed sensor and is fixedly mounted on the large bottom plate 3 through screws. The spindle servo motor selects a high-precision Mitsubishi (or same precision brand) finished product, and the rotating speed sensor selects a high-precision ohm dragon (or same precision brand) finished product.

Further, as shown in fig. 5 and 6, the winding length detection mechanism 6 is composed of an encoder 601, a length detection mounting plate 602, three wire arranging wheels 603, two wire passing wheels 604, an encoder transmission wheel 605, a wire pressing synchronous belt 606, three synchronous belt wheels 607 and the like. The encoder 601 is connected with the encoder driving wheel 605, and the line pressing synchronous belt 606 is connected with the encoder driving wheel 605 and three synchronous belt wheels 607

Before winding, the encoder driving wheel 605 is wound by one circle, during winding, the wire pressing synchronous belt 606 compresses the enameled wire, the enameled wire drives the encoder driving wheel 605 to rotate, and the encoder 601 counts, so that an accurate enameled wire length value is obtained. By the length value of the enameled wire, the PLC software in the touch screen on the spindle box 4 can calculate the accurate resistance value of the coil according to the formula R = rho x (L1 + L2)/S + R1, and the touch screen displays the value. (the resistivity rho =0.0172 of the copper wire, L1 is the length of the enameled wire to be measured, L2 is the length of the starting wire, S is the cross section area of the enameled wire, and R1 is the compensation resistance). In order to reduce friction, the wire discharging wheel 603, the wire passing wheel 604, the encoder driving wheel 605 and the synchronous pulley 607 are all mounted on the length detection mounting plate 602 by adopting high-precision ball bearings. The length detection mounting plate 602 is fixed to the wire feeding mechanism 7 by screws.

Further, as shown in fig. 7 and 8, the wire feeding mechanism 7 includes a wire feeding precision linear module 701, a wire feeding servo motor 702, a wire feeding mounting plate 703, an adjustable wire arranging wheel 704, and the like.

The wire arranging mechanism 8 comprises a mounting seat 801, a wire arranging precision linear module 802, a wire arranging servo motor 803 and the like.

The wire feeding precision linear module 701 and the wire arranging precision linear module 802 are both manufactured by a precision worm gear and a square-shaped beam; the adjustable wire arranging wheel 704 comprises a supporting rod, a wire arranging needle nozzle and an intermediate shaft.

In the wire feeding mechanism 7, the adjustable wire arranging wheel 704 is fixedly mounted on the wire feeding mounting plate 703 through a mounting bracket and a screw, the wire feeding mounting plate 703 is fixedly mounted on the wire feeding precise linear module 701 through a screw (substantially, the wire feeding mounting plate 703 is fixed on a turbine in the wire feeding precise linear module 701), and the wire feeding servo motor 702 is connected with the wire feeding precise linear module 701 through a coupler (substantially, an output shaft of the wire feeding servo motor 702 is connected with a worm in the wire feeding precise linear module 701 through a coupler) and is fixed by a screw and a flange.

In the wire arranging mechanism 8, the wire arranging servo motor 803 is connected with the wire arranging precise linear module 802 through a coupler (substantially, an output shaft of the wire arranging servo motor 803 is connected with a worm in the wire arranging precise linear module 802 through a coupler), and is fixed by a screw and a flange. The upper part of the wire arranging mechanism 8, the wire feeding precision linear module 701 in the wire feeding mechanism 7 is connected with the wire arranging precision linear module 802 through a connecting plate (essentially, the wire feeding precision linear module 701 is fixed on a turbine in the wire arranging precision linear module 802 through the connecting plate) and is fixed by screws. The lower part of the wire arranging mechanism 8 is fixedly arranged on the large bottom plate 3 through an I-shaped mounting seat 801 by screws.

The wire feeding mechanism 7 is arranged according to the number of layers of coils wound by the electromagnet, the wire feeding servo motor 702 drives the wire feeding precise linear module 701 to drive the adjustable wire arranging wheel 704 to move longitudinally (in the Y direction), the wire feeding distance of a wire arranging needle nozzle is controlled, and the wire diameter distance can be automatically retreated for each winding layer, so that collision can be avoided when a product winds more and more, and the maximum diameter of the wire feeding mechanism 7 which can rotate back is 200mm.

The winding displacement mechanism 8 is arranged according to the groove width of the wound electromagnet coil, and the winding displacement servo motor 803 drives the winding displacement precise linear module 802 to drive the wire feeding mechanism 7 and the adjustable winding displacement wheel 704 thereof to move transversely (in the X direction). When the spindle in the spindle box 4 rotates once along with an output instruction of the spindle speed sensor in the spindle box 4, the winding displacement servo motor 803 drives the winding displacement precise linear module 802 to drive the adjustable winding displacement wheel 704 to move a linear diameter distance transversely (in the X direction), and the stroke range of the winding displacement mechanism 8 is 0-200 mm.

The middle shaft of the adjustable wire arranging wheel 704 is inserted into the bracket and is slightly screwed by a screw, so that the proper height (Z direction) of the wire arranging needle nozzle can be manually adjusted. The wire arranging needle nozzle is made of wear-resistant tungsten steel, and the surface of an inner hole is precisely ground and processed by abrasive flow (Ra0.4) so as to avoid the abrasion or scratch damage of an enameled wire.

As shown in fig. 9, the servo motor active wire feeding tensioner 9 selects the model SF600, actively feeds the wire along with the speed of the main shaft of the winding device, the tension is stable, the enameled wire cannot be mistakenly thinned due to the tension, the following precision is high, and the response is fast. Tension range: 20-450g.

The tensioner frame 10 is made of angle steel and steel plates and subjected to plastic spraying treatment, and the height is 980mm. The upper end of the tensioner frame 10 is used for installing a servo motor active wire feeding tensioner 9, and the lower part of the tensioner frame is 600mm (length) multiplied by 500mm (width) multiplied by 50mm (height) and used for placing an enameled wire.

An application method of the electromagnet winding device is applied to the electromagnet winding device, and the electromagnet winding is carried out by taking the electromagnet framework shown in fig. 12 as an example.

The power supply voltage of the electromagnet winding device is 220V +/-10%, and the middle inserting core of the single power line three-core plug is reliably grounded. The air pressure of the air source is 1MPa +/-10%.

The control system of the electromagnet winding device is characterized in that a PLC serves as a main controller, a touch screen on a spindle box 4 serves as a man-machine friendly interaction interface, the winding system utilizes the man-machine interaction touch screen to realize operation, and the realized functions comprise single-action and linkage action of each system, inching operation, linkage operation, forward and reverse rotation setting of winding and unwinding, left and right movement setting of winding and unwinding, speed and wire diameter setting, single-layer operation, multi-layer continuous operation and the like. The moving part comprises a wire collecting main shaft moving part, a wire feeding shaft moving part, a wire arrangement frame lifting part, a wire arrangement left-right moving part and the like.

The method comprises the following specific steps:

and (I) selecting a corresponding matched rotating shaft according to the type of the electromagnet framework, inserting the rotating shaft into the main shaft hole, screwing down the rotating shaft through a locking screw, and clamping the electromagnet framework through the rotating shaft and the tail jacking mechanism 2.

Specifically, the rotating shaft is screwed by a locking screw after being inserted into the spindle hole, the jumping quantity of the rotating shaft is measured to ensure the rotating coaxiality of the rotating shaft, the jumping quantity is not more than 0.05mm, and the framework is not eccentric during winding. The center of the tail ejecting mechanism 2 and the central axis of the rotating shaft should be coaxial, when the handle is loosened to move the tail ejecting mechanism 2, the center lightly touches the top cover, then the handle is rotated clockwise to be locked, and then the voltage stabilizer outputs 0.5-0.6 MPa, the rotating speed of the main shaft is 0-500 rpm (determined according to the wire diameter), and the wire diameter range can be 0.1-1.0 mm.

And (II) placing the enameled wire coil at the bottom of the tensioner frame 10, leading the wire drawing head into the winding length detection mechanism 6 after passing through the wire feeding wheel of the servo motor active wire feeding tensioner 9, passing through two wire passing wheels 604, passing between an encoder driving wheel 605 and a synchronous pulley 607, then passing through the two wire passing wheels 604, sequentially passing through three wire arranging wheels 603, sequentially passing the wire head through an adjustable wire arranging wheel 704 on the wire feeding mechanism 7 and a wire arranging needle nozzle in the adjustable wire arranging wheel, placing the enameled wire close to the wire arranging wheel into a wire leading-out groove on an electromagnet framework to be slightly tensioned, winding the head of the enameled wire on a rotating shaft locking screw for one circle, bonding the head of the wire on the rotating shaft by using paper adhesive tape to prevent loosening, rotating the rotating shaft for one circle, and uniformly winding the end of the enameled wire, as shown in fig. 10. The direction of the rotating shaft can be in the positive rotation or the negative rotation, but the rotating direction is required to be consistent with the rotating direction set by a subsequent program.

In the winding process of the step (III), the winding length detection mechanism 6 detects the winding length of the enameled wire, PLC software in a touch screen on the spindle box 4 calculates the resistance of the coil and displays the value, and whether the resistance of the electromagnet coil meets the technical index requirement is judged. The servo motor active wire feeding tensioner 9 actively feeds wires along with the speed of the main shaft on the main shaft box 4, the tension is stable, and the enameled wires cannot be mistakenly thinned due to the tension.

In the winding process of the step (four), the wire feeding servo motor 702 drives the wire feeding precise linear module 701 to drive the adjustable wire arranging wheel 704 to move longitudinally (in the Y direction), and the wire feeding distance of the wire arranging needle nozzle on the adjustable wire arranging wheel 704 is controlled, so that each wound layer can automatically retreat by one wire diameter distance. The maximum rotatable diameter of the wire feeding mechanism 7 is 200mm.

The left and right moving part of the wire arranging is realized by the wire arranging mechanism 8 along with the output instruction of a main shaft rotating speed sensor in the main shaft box 4. The wire arranging system consists of a position ring, a speed ring and a current ring. The position loop is used to compare a given position with the actual feedback position of the motor to meet the minimum error requirement. The speed loop adjusts the motor current, namely the motor speed in real time according to the feedback quantity. The speed of the speed loop determines the dynamic response speed of the overall system. The current loop is mainly used for calculating the torque of motor transmission, and parameters can be automatically optimized and set according to motor data stored in advance. When the spindle rotates one turn, the winding displacement servo motor 803 drives the winding displacement precise linear module 802 to drive the adjustable winding displacement wheel 704 to move a linear diameter distance in the transverse direction (X direction).

Further, as shown in fig. 11, the height of the winding pin nozzle in the adjustable winding wheel 704 can be manually adjusted. So that when the enameled wire is wound and the framework is fully wound, the scientific and reasonable bevel angle at the needle tube is between 5 and 20 degrees. When the folding angle of the enameled wire is too small, the wire arrangement is not easy to be tidy; when the enameled wire dog-ear is too big, the enameled wire is too big in needle tubing department atress, grinds the line easily, and the needle tubing generates heat, and the needle tubing also wears easily simultaneously.

When the wire arranging mechanism 8 moves along the X direction, an error is generated, and when the movement accumulated error exceeds the distance of three turns of diameter, the error is processed in time.

Specifically, winding displacement mechanism 8 removes and is related to enameled wire external diameter size (including the coating with lacquer thickness, with the micrometer actual measurement), and the main shaft rotates the round, and winding displacement mechanism 8 removes the displacement of an enameled wire external diameter size, and electromagnet winding device records a circle. Due to the influence of the uniformity of the outer diameter of the enameled wire and the control precision of the servo system, the movement of the wire arranging mechanism 8 generates errors, the errors are accumulated to a certain degree, and wire jumping or loose arrangement can occur in the enameled wire winding process, so that the coil winding fails. Therefore, when the accumulated moving error of the traverse mechanism 8 exceeds the 3-turn diameter distance, the accumulated moving error should be processed in time.

Further, the specific processing procedure of the movement accumulated error of the traverse mechanism 8 is as follows: firstly pressing a start/stop key in a touch screen on a headstock 4 to pause winding, then pressing a "←" key or a "→" key in the touch screen on the headstock 4 to change the position of a wire arranging mechanism 8, and simultaneously adopting a piecewise fitting method to perform nonlinear expression on the relationship between input quantity and output quantity stepping motors of a spindle motor rotating for one circle, and setting parameters in layers according to the enameled wire state on the number of layers, namely: the pulse number of the unit wire diameter is distributed to a plurality of states for control, the complete synchronization of the wire arranging device with the main shaft motor in unit turns is achieved, and the movement accumulated error of the wire arranging mechanism 8 is eliminated.

And step (six) repeating the step (four) to the step (five) until the set winding number is finished.

The foregoing shows and describes the general principles, essential features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are merely illustrative of the principles of the invention, but that various changes and modifications may be made without departing from the spirit and scope of the invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.

Claims (10)

1. An electro-magnet winding device which characterized in that: comprises a frame (1) and a tensioner frame (10);

the wire winding machine is characterized in that a large bottom plate (3) is arranged at the top of the rack (1), a tail ejection mechanism (2), a spindle box (4), a wire winding motor (5) and a wire arrangement mechanism (8) are correspondingly arranged on the large bottom plate (3), the tail ejection mechanism (2) and the spindle box (4) are oppositely arranged, the wire winding motor (5) is connected with the spindle box (4), a wire feeding mechanism (7) is slidably mounted on the wire arrangement mechanism (8), a wire winding length detection mechanism (6) is fixedly mounted on the wire feeding mechanism (7), and the wire arrangement mechanism (8) is located at a side position between the tail ejection mechanism (2) and the spindle box (4);

the upper end part of the tensioner frame (10) is fixedly provided with a servo motor active wire feeding tensioner (9), and the bottom of the tensioner frame (10) is provided with an enameled wire;

the enameled wire is followed servo motor initiatively sends out process in line tensioner (9) the wire winding length detection mechanism (6) carry out the enameled wire length and calculate the back, through send line mechanism (7), winding displacement mechanism (8) to carry out X direction and Y direction wire winding direction, and the cooperation tail top mechanism (2) with headstock (4) clamping electromagnetism iron frame and drive electromagnetism iron frame and rotate in order to realize the electro-magnet wire winding.

2. An electromagnet winding device as defined in claim 1, wherein: the tail top mechanism (2) comprises a sliding rail (203) fixedly mounted on the large bottom plate (3), a sliding block (201) slidably mounted on the sliding rail (203), an air cylinder support (204) arranged on the sliding block (201), and an air source support (208), wherein an air cylinder (206) is mounted on the air cylinder support (204), the air cylinder (206) is connected with a top (205), an air source stabilizer (207) is mounted on the air source support (208), a locking mechanism (202) is arranged on the sliding block (201), and the output air pressure of the air source stabilizer (207) is 0.5-0.6 MPa.

3. An electromagnet winding apparatus as defined in claim 1 wherein: the winding machine is characterized in that a main shaft connected with the winding motor (5) is arranged inside the main shaft box (4), the main shaft is connected with a rotating shaft in a detachable connection mode, and a touch screen is arranged outside the main shaft box (4).

4. An electromagnet winding apparatus as defined in claim 3 wherein: winding motor (5) are including fixed mounting winding motor mounting bracket on big bottom plate (3), install main shaft servo motor on the winding motor mounting bracket, with the tachometric sensor that main shaft servo motor connects, main shaft servo motor pass through the gear with main shaft in headstock (4) is connected.

5. An electromagnet winding device as defined in claim 1, wherein: wire winding length detection mechanism (6) are including fixed mounting send length detection mounting panel (602), setting on the line mechanism (7) to be in encoder (601), three wire arranging wheel (603), two wire guide wheels (604), encoder drive wheel (605), line ball hold-in range (606), three synchronous pulley (607) on length detection mounting panel (602), encoder (601) with encoder drive wheel (605) are connected, line ball hold-in range (606) with encoder drive wheel (605), three synchronous pulley (607) are connected.

6. An electromagnet winding apparatus as defined in claim 5 wherein: the wire feeding mechanism (7) comprises a wire feeding precise linear module (701) arranged on the wire arranging mechanism (8), a wire feeding servo motor (702) connected with the wire feeding precise linear module (701) through a coupler, a wire feeding mounting plate (703) connected with the wire feeding precise linear module (701), and an adjustable wire arranging wheel (704) connected to the wire feeding mounting plate (703), wherein the wire winding length detection mechanism (6) is connected to the wire feeding mounting plate (703).

7. An electromagnet winding apparatus as set forth in claim 6, wherein: the wire arranging mechanism (8) comprises a mounting seat (801) fixedly mounted on the large bottom plate (3), a wire arranging precise linear module (802) fixedly mounted on the mounting seat (801), and a wire arranging servo motor (803) connected with the wire arranging precise linear module (802) through a coupler, wherein the wire feeding precise linear module (701) is mounted on the wire arranging precise linear module (802) through a connecting plate.

8. An electromagnet winding device as defined in claim 1, wherein: the type of the servo motor active wire feeding tensioner (9) is SF600, and the tension range is 20-450g.

9. An electromagnet winding process method is characterized in that: the electromagnet winding device according to any one of claims 1 to 8, comprising the following steps:

selecting a corresponding matched rotating shaft according to the type of the electromagnet framework, inserting the rotating shaft into a main shaft hole, screwing the rotating shaft through a locking screw, and clamping the electromagnet framework through the rotating shaft and a tail jacking mechanism (2);

secondly, placing an enameled wire coil at the bottom of a tensioner frame (10), leading a wire drawing head into a winding length detection mechanism (6) after passing through a wire feeding wheel of a servo motor active wire feeding tensioner (9), leading the wire drawing head through two wire passing wheels (604), passing between an encoder driving wheel (605) and a synchronous belt wheel (607), then passing out of the two wire passing wheels (604), sequentially passing through three wire arranging wheels (603), sequentially passing the wire head through an adjustable wire arranging wheel (704) on a wire feeding mechanism (7) and a wire arranging needle nozzle in the adjustable wire arranging wheel (704), placing the enameled wire into a wire leading-out groove on an electromagnet framework for slight tensioning, winding the head of the enameled wire on a rotating shaft locking screw for one circle, bonding the head of the wire on the rotating shaft by using paper tape to prevent loosening, rotating the rotating shaft for one circle, and uniformly arranging the end of the enameled wire;

in the winding process of the step (III), a winding length detection mechanism (6) detects the winding length of the enameled wire, a touch screen on a spindle box (4) calculates the resistance of the coil and displays the value, and whether the resistance of the electromagnet coil meets the technical index requirement is judged;

in the winding process of the fourth step, when one layer is wound, the wire arranging needle nozzle in the adjustable wire arranging wheel (704) automatically retreats for a wire diameter distance along the Y direction, and when the main shaft rotates for one circle, the wire arranging needle nozzle in the adjustable wire arranging wheel (704) automatically moves for a wire diameter distance along the X direction under the driving of the wire arranging mechanism (8);

step five, errors are generated when the wire arranging mechanism (8) moves along the X direction, and when the movement accumulated errors exceed the three-turn diameter distance, the errors are processed in time;

and step (six) repeating the step (four) to the step (five) until the set winding number is finished.

10. The electromagnet winding process method according to claim 9, characterized in that: the concrete processing process of the movement accumulated error of the wire arranging mechanism (8) in the step (five) is as follows: the method comprises the steps of firstly pressing a start/stop key in a touch screen on a spindle box (4) to pause winding, then pressing a '←' key or a '→' key in the touch screen on the spindle box (4) to change the position of a wire arranging mechanism (8), and meanwhile adopting a piecewise fitting method to carry out nonlinear expression on the relation between input quantity and output quantity stepping motors of a spindle motor rotating for one circle, and setting parameters in layers according to the enameled wire state on the number of layers to synchronize the wire arranging mechanism (8) with the spindle motion, so that the motion accumulated error of the wire arranging mechanism (8) is eliminated.

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