CN117393313A - Zero-flux coil winding operation production process - Google Patents
Zero-flux coil winding operation production process Download PDFInfo
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- CN117393313A CN117393313A CN202311555827.4A CN202311555827A CN117393313A CN 117393313 A CN117393313 A CN 117393313A CN 202311555827 A CN202311555827 A CN 202311555827A CN 117393313 A CN117393313 A CN 117393313A
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- 238000004804 winding Methods 0.000 title claims abstract description 197
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 45
- 229910052782 aluminium Inorganic materials 0.000 claims description 45
- 239000002390 adhesive tape Substances 0.000 claims description 38
- 150000002466 imines Chemical class 0.000 claims description 34
- 238000005520 cutting process Methods 0.000 claims description 28
- 239000002023 wood Substances 0.000 claims description 25
- 238000010009 beating Methods 0.000 claims description 10
- 238000005452 bending Methods 0.000 claims description 9
- 230000009194 climbing Effects 0.000 claims description 6
- 238000001125 extrusion Methods 0.000 claims description 6
- 238000000034 method Methods 0.000 claims description 6
- 238000007493 shaping process Methods 0.000 claims description 6
- 230000004907 flux Effects 0.000 claims description 5
- 230000002093 peripheral effect Effects 0.000 claims description 5
- 229910000831 Steel Inorganic materials 0.000 claims description 4
- 238000003825 pressing Methods 0.000 claims description 4
- 239000010959 steel Substances 0.000 claims description 4
- 238000005259 measurement Methods 0.000 claims 1
- 238000005339 levitation Methods 0.000 abstract description 5
- 230000032683 aging Effects 0.000 abstract description 4
- 239000000725 suspension Substances 0.000 abstract 2
- 230000002035 prolonged effect Effects 0.000 abstract 1
- 238000010586 diagram Methods 0.000 description 6
- 239000004411 aluminium Substances 0.000 description 5
- 239000011257 shell material Substances 0.000 description 4
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000006467 substitution reaction Methods 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 239000004484 Briquette Substances 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000009191 jumping Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 238000004904 shortening Methods 0.000 description 1
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/071—Winding coils of special form
- H01F41/074—Winding flat coils
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/076—Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/082—Devices for guiding or positioning the winding material on the former
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/09—Winding machines having two or more work holders or formers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/098—Mandrels; Formers
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
The invention relates to the technical field of magnetic suspension, in particular to a production process for zero-flux coil winding operation, which adopts two windings to wind an upper coil and a lower coil respectively, and the upper coil and the lower coil are arranged as double-layer coils of an upper loop and a lower loop, so that the zero-flux coil with good performance can be produced rapidly and efficiently through the production process, levitation force with smaller fluctuation range can be provided for a magnetic suspension train, and the coil outlet heads of the upper coil and the lower coil are combined together to serve as a hinge joint, so that the hinge joint is not required to be additionally introduced, the ageing of a shell is slowed down, and the service time of the zero-flux coil is prolonged.
Description
Technical Field
The invention relates to the technical field, in particular to a production process for winding operation.
Background
In a magnetic levitation track traffic system, zero-flux coils are also called splayed coils, the zero-flux coils provide levitation force and guiding force for a train, and the zero-flux coils arranged on two sides of a track beam are connected through hinge lines. When the train is laterally offset, the current in the hinge line is correspondingly changed due to the change of the current in the zero-flux coils at the two sides of the track, so that the guiding rigidity of the zero-flux coils is changed, and the train is always kept at the center position of the zero-flux coils at the two sides of the track.
For a zero-flux coil operating in a vacuum environment, when there is a zero-flux coil swept by the superconducting magnet, the zero-flux coil may also generate heat due to its own material properties after normal operation. In a vacuum environment, the heat of the zero-flux coil is difficult to dissipate, and the zero-flux coil shell (usually cast by epoxy resin) can age and lose effect over time, so that the zero-flux coil cannot work normally.
The hinge heads are arranged between the current zero-magnetic-flux coil and the hinge line and are used for connecting the zero-magnetic-flux coil and the hinge line, one end of each hinge head is connected with the middle part of the zero-magnetic-flux coil, the other end of each hinge head is connected with the hinge line to form two connecting joints, and the joint connection mode of each hinge head and each zero-magnetic-flux coil can directly influence the heating condition of the zero-magnetic-flux coil; the existing hinge head and the zero-magnetic-flux coil are generally connected by welding, riveting or bolting. However, the resistance of the joint in the welding mode is larger, the temperature rise of the joint is fastest when the zero-flux coil works normally, and the ageing of the shell material of the joint is fastest, so that the service life of the zero-flux coil is further shortened. The joint of riveting or bolting also has larger contact resistance, so that the temperature rise of the joint is fastest, and the ageing of the shell material of the joint is fastest, thereby further shortening the service life of the zero-flux coil.
Disclosure of Invention
In order to solve some problems in the prior art, the invention provides a production process for zero-flux coil winding operation, which solves the defects in the prior art.
In order to achieve the above purpose, the invention provides a production process for zero-flux coil winding operation, which comprises the following steps:
step one: the method comprises the steps of sequentially installing a winding backboard and an aluminum winding die, enabling the winding backboard and the aluminum winding die to be completely and tightly attached, installing a square limiting clamping plate, checking the initial center lines of the winding backboard and the aluminum winding die, and guaranteeing the coincidence of the winding backboard and the initial center line of the aluminum winding die;
step two: installing a pre-winding wood disc, pulling out wire heads from a main wire disc, inserting a bayonet of the pre-winding wood disc, measuring by using a tape measure, pre-winding 18 meters of 12 turns of coils, pre-winding 17 meters of 11 turns of coils, and marking after the pre-winding is finished;
step three: when the pre-winding length is reached, marking the corresponding position by using a red pen, and then repeatedly and symmetrically finding a chain line from the marking position to two ends respectively, wherein the continuous size chain is 160mm, 260mm, 340mm and 260mm, and the corresponding position is marked by using the red pen;
step four: taking the pre-winding end mark points as central lines, winding imine adhesive tapes between the two 160 mark points, winding 70mm imine adhesive tapes on the other side of the 160 mark points, winding 70mm imine adhesive tapes on the two ends of the 260 mark points, winding 70mm imine adhesive tapes on the two ends of the 340mm mark points, winding 70mm imine adhesive tapes on one end of the central line, and winding 200mm imine adhesive tapes on the other end of the central line;
step five: placing a limiting climbing layer positioning block, wherein one end of the limiting block is 25mm away from the central line, and sticking and fixing the limiting block by using an imine adhesive tape;
step six: the method comprises the steps of enabling a pre-winding length marking line to correspond to the center line of a winding mold, enabling an inner turn line to be tightly attached to a winding backboard, enabling an outer turn line to be pulled outwards, staggering one line width, knocking the line by using a cushion block, enabling the line to be flatly attached to an aluminum mold, placing a wooden pressing block, and clamping two F-shaped quick clamps at the starting position of winding;
step seven: after the wire is bent, a rubber hammer is used for knocking to enable the aluminum wire to be flat, the aluminum wire is flatly attached to a winding die, and the inner turn wire is tightly attached to a winding backboard;
step eight: turning on a tension button, turning on a foot switch, starting to wind a first layer of coil by anticlockwise rotation of the equipment, leveling the wire from a round corner by using a knocking base plate after every 90 degrees of rotation, knocking the upper surface of the wire to enable the wire to be tightly attached to an R angle, transversely placing the knocking base plate when the straight line section is leveled, increasing the contact surface with the wire, knocking the upper end of the base plate by using a rubber hammer, sequentially knocking from left to right, pushing the gap between the wire and an inner die to one side of the wire outgoing disc, loosening and taking off two F-shaped quick clamps and a wood cushion block at the initial position after 270 degrees of rotation of the first circle, and then turning the wire to jump a second layer by 90 degrees;
step nine: repeating the first winding step of the inner layer, loosening the F-shaped quick clamp and the wood cushion block with the line reaching the surface in advance, beating the line by using a beating base plate to cling to a circle of line, starting to flatten the line from the R angle, and sequentially starting to flatten the line from left to right, wherein the coil width direction needs to be beaten and flattened along with the increase of the winding number, so that the width direction is cling to the winding backboard until the preset number of turns is wound;
step ten: winding to reach the required number of turns, detecting the thickness of the wire to reach the requirement, cutting the wire from a main wire spool, wherein the cutting starting point is the central line of a winding mould, the cutting length of a 12-turn coil from the central line is 1380mm, the cutting length of an 11-turn coil from the central line is 980mm, winding the redundant wire head to the outer side of the coil after cutting, wrapping the head by using an adhesive tape, detaching the pre-winding disc from a square shaft of a winding machine, installing the pre-winding disc on an auxiliary winding frame, and preparing to wind a second-layer coil;
step eleven: beating the outer turn coil by using a cushion block, enabling the outer edge of the wire to be flush with an aluminum die, placing a wood cushion block, clamping by using two F-shaped quick clamps, and repeating the winding step of the first layer coil;
step twelve: two groups of zero magnetic flux coils are combined, the upper coil is a 12-turn coil, the lower coil is an 11-turn coil, the two groups of coils are combined into a whole, and the middle is fixed by two F-shaped quick clamps;
step thirteen: the assembled coils are put into a wooden tray together, and 3F-shaped quick clamps are used for fixing the coils on two right-angle edges of the wooden tray;
step fourteen: winding the extension part of the 12-turn coil on the outer side of the 11-turn coil, fixing the extension part by using an F-shaped quick clamp, marking the position of an outgoing line elbow by using a steel plate ruler, bending the wire head to the position of the marked wire by using a wire bending tool, marking the reserved length of the wire head by using a red pen, cutting off the redundant wire head by using a high-force shear, tightly winding the extension part of the 12-turn coil on the outer side of the 11-turn coil, and fixing the R-angle by using the F-shaped quick clamp at the same time;
fifteen steps: reserving the length of the wire ends by 100mm, cutting the insulating layer by a blade with the front end of 70mm, stripping the insulating layer, leveling the two groups of wire ends by a rubber hammer, enabling the surfaces of the two groups of wire ends to be clung, and binding and fixing the two groups of wire ends by an imine adhesive tape;
step sixteen: the combined coil is placed in an extrusion shaping tool, the peripheral sliding blocks are adjusted, the positions of the sliding blocks are adjusted to the maximum size position when the combined coil is placed in the coil, the coil is prevented from being damaged by collision, the combined coil is extruded and shaped to the required size, and the size is measured by a vernier caliper, so that the size requirement is 880 x 480.
When the aluminum wire winding die works, the wire winding backboard and the aluminum wire winding die are sequentially installed, so that the wire winding backboard and the aluminum wire winding die are completely and tightly attached, the square limiting clamping plate is installed, the initial center lines of the wire winding backboard and the aluminum wire winding die are checked, and the coincidence of the initial center lines of the wire winding backboard and the aluminum wire winding die is ensured; the method comprises the steps of installing a pre-winding wood disc, pulling out wire heads from a main wire winding disc, inserting a pre-winding wood disc bayonet, measuring by using a tape measure, pre-winding 18 m wires by 12 turns of coils, pre-winding 17 m wires by 11 turns of coils, finishing the pre-winding and marking, respectively winding 12 turns of coils and 12 turns of coils, combining two groups of zero-magnetic-flux coils, wherein an upper coil is the 12 turns of coils, a lower coil is the 11 turns of coils, combining the two groups of coils into a whole, fixing the two F-shaped fast clamps in the middle, putting the combined coils into a wood tray, fixing the coils on two right-angle sides of the wood tray by using 3F-shaped fast clamps, putting the combined coils into an extrusion shaping tool, adjusting peripheral sliding blocks, adjusting the positions of the sliding blocks to the maximum size position when the coils are in order to prevent the coils from being damaged, extruding the coils to the required size, and measuring by using a vernier caliper.
The invention has the beneficial effects that: the invention provides a production process for zero-flux coil winding operation, which adopts two windings to wind an upper coil and a lower coil respectively, and double-layer coils with the upper coil and the lower coil being arranged as an upper loop and a lower loop can rapidly and efficiently produce the zero-flux coil with good performance through the production process, can provide levitation force with smaller fluctuation range for a magnetic levitation train, adopts the joint combination of wire outlet heads of the upper coil and the lower coil as a hinge joint, does not need to additionally introduce a hinge joint, slows down the aging of a shell, and improves the service time.
Drawings
For the convenience of those skilled in the art, the present invention will be further described with reference to the accompanying drawings:
fig. 1 is a structural diagram of the present invention.
Fig. 2 is an assembly view of a square limiting clamp plate and an aluminum winding former.
Fig. 3 is a placement structure diagram of the climbing layer positioning block.
Fig. 4 is a structural diagram of an F-type quick clamp holding aluminum wire.
Fig. 5 is a process diagram of flattening an aluminum wire.
Fig. 6 is a placement structure of the wood briquette.
Fig. 7 is a structural view of a wound first layer coil.
Fig. 8 is a structural diagram when the number of winding layers increases.
Fig. 9 is a structural view when the number of winding turns is reached.
Fig. 10 is a structural diagram of the extrusion shaping tool.
Wherein, 1 wire winding backplate, 2 aluminium wire winding moulds, 3 square spacing splint, 4 climb layer locating piece, 5 wooden briquetting, 6F formula quick clamp, 7 sliders.
Detailed Description
In order to better understand the technical solutions in the present application, the following description is further described with reference to fig. 1 to 10, and the following examples are only used to more clearly illustrate the technical solutions of the present invention, and should not be construed to limit the scope of the present invention.
In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are merely for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present invention; furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated; thus, a feature defining "a first", "a second", etc. may explicitly or implicitly include one or more such feature; in the description of the present invention, unless otherwise indicated, the meaning of "a plurality" is two or more.
In the description of the present invention, it should be noted that, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be the communication between the two elements; the specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art in a specific case.
A zero flux coil winding operation production process as shown in fig. 1-10, comprising a production process comprising the steps of:
step one: the winding backboard 1 and the aluminum winding former 2 are sequentially installed, so that the winding backboard 1 and the aluminum winding former 2 are completely and tightly attached, the square limiting clamping plate 3 is installed, initial center lines of the winding backboard 1 and the aluminum winding former 2 are checked, and the winding backboard 1 and the initial center line of the aluminum winding former 2 are ensured to coincide;
step two: installing a pre-winding wood disc, pulling out wire heads from a main wire disc, inserting a bayonet of the pre-winding wood disc, measuring by using a tape measure, pre-winding 18 meters of 12 turns of coils, pre-winding 17 meters of 11 turns of coils, and marking after the pre-winding is finished;
step three: when the pre-winding length is reached, marking the corresponding position by using a red pen, and then repeatedly and symmetrically finding a chain line from the marking position to two ends respectively, wherein the continuous size chain is 160mm, 260mm, 340mm and 260mm, and the corresponding position is marked by using the red pen;
step four: taking the pre-winding end mark points as central lines, winding imine adhesive tapes between the two 160 mark points, winding 70mm imine adhesive tapes on the other side of the 160 mark points, winding 70mm imine adhesive tapes on the two ends of the 260 mark points, winding 70mm imine adhesive tapes on the two ends of the 340mm mark points, winding 70mm imine adhesive tapes on one end of the central line, and winding 200mm imine adhesive tapes on the other end of the central line;
step five: placing a limiting climbing layer positioning block 4, wherein one end of the limiting block is 25mm away from the central line, and adhering and fixing the limiting block by using an imine adhesive tape;
step six: the pre-winding length marking wire corresponds to the central line of a winding mould, the inner turn wire is tightly attached to the winding backboard 1, the outer turn wire is pulled outwards, the line width is staggered, the wire is knocked by using a cushion block, the wire is flatly attached to the aluminium mould, a wooden pressing block 5 is placed, and the winding starting position is clamped and clamped by two F-shaped quick clamps 6;
step seven: after the wire is bent, a rubber hammer is used for knocking to enable the aluminum wire to be flat, the aluminum wire is flatly attached to a winding die, and the inner turn wire is tightly attached to the winding backboard 1;
step eight: turning on a tension button, turning on a foot switch, starting to wind a first layer of coil by anticlockwise rotation of the equipment, leveling the wire from a round corner by using a knocking base plate after every 90 degrees of rotation, knocking the upper surface of the wire to enable the wire to be tightly attached to an R angle, transversely placing the knocking base plate when the straight line section is leveled, increasing the contact surface with the wire, knocking the upper end of the base plate by using a rubber hammer, sequentially knocking from left to right, pushing the gap between the wire and an inner die to one side of the wire outgoing disc, loosening and taking off two F-shaped quick clamps 6 and a wood cushion block at the initial position after 270 degrees of rotation of the first circle, turning the wire to jump a second layer by 90 degrees;
step nine: repeating the first winding step of the inner layer, loosening and taking off the wire to reach the F-shaped quick clamp 6 and the wood cushion block in advance, beating the wire by using a beating base plate to cling to a circle of wire, starting to level the wire from the R angle, and sequentially from left to right, wherein the coil width direction needs to be beaten and leveled along with the increase of the winding number, so that the width direction is cling to the winding backboard 1 until the preset number of turns is wound;
step ten: winding to reach the required number of turns, detecting the thickness of the wire to reach the requirement, cutting the wire from a main wire spool, wherein the cutting starting point is the central line of a winding mould, the cutting length of a 12-turn coil from the central line is 1380mm, the cutting length of an 11-turn coil from the central line is 980mm, winding the redundant wire head to the outer side of the coil after cutting, wrapping the head by using an adhesive tape, detaching the pre-winding disc from a square shaft of a winding machine, installing the pre-winding disc on an auxiliary winding frame, and preparing to wind a second-layer coil;
step eleven: beating the outer turn coil by using a cushion block, arranging a wood cushion block at the outer side edge of the wire and being flush with an aluminum die, clamping by using two F-shaped quick clamps 6, and repeating the winding step of the first layer of coil;
step twelve: two groups of zero magnetic flux coils are combined, the upper coil is a 12-turn coil, the lower coil is an 11-turn coil, the two groups of coils are combined into a whole, and the middle is fixed by two F-shaped quick clamps 6;
step thirteen: the assembled coils are put into a wooden tray together, and 3F-shaped quick clamps 6 are used for fixing the coils on two right-angle sides of the wooden tray;
step fourteen: winding the extension part of the 12-turn coil on the outer side of the 11-turn coil, fixing the extension part by using an F-shaped quick clamp 6, marking the position of a wire outlet elbow by using a steel plate ruler, bending the wire head to the position of the marked wire by using a wire bending tool, marking the reserved length of the wire head by using a red pen, cutting off the redundant wire head by using a high-force shear, tightly winding the extension part of the 12-turn coil on the outer side of the 11-turn coil, and fixing the R-angle by using the F-shaped quick clamp 6 at the same time;
fifteen steps: reserving the length of the wire ends by 100mm, cutting the insulating layer by a blade with the front end of 70mm, stripping the insulating layer, leveling the two groups of wire ends by a rubber hammer, enabling the surfaces of the two groups of wire ends to be clung, and binding and fixing the two groups of wire ends by an imine adhesive tape;
step sixteen: the combined coil is placed into an extrusion shaping tool, the peripheral sliding blocks 7 are adjusted, the positions of the sliding blocks 7 are adjusted to the maximum size position when the combined coil is placed into the coil, the coil is prevented from being damaged by collision, the combined coil is extruded and shaped to the required size, and the combined coil is measured by a vernier caliper, so that the size is 880 x 480.
When the invention works, the winding backboard 1 and the aluminum winding die 2 are sequentially arranged, so that the winding backboard 1 and the aluminum winding die 2 are completely and tightly attached, the square limiting clamp plate 3 is arranged, the initial central lines of the winding backboard 1 and the aluminum winding die 2 are checked, the coincidence of the initial central lines of the winding backboard 1 and the aluminum winding die 2 is ensured, the pre-winding wood disc is arranged, the wire head is pulled out from the main winding disc, the bayonet of the pre-winding wood disc is inserted, the measuring tape is used for measuring, the 12-turn coil is pre-wound by 18 meters, the 11-turn coil is pre-wound by 17 meters, the pre-winding is finished and marked, the pre-winding length is reached, the corresponding position is marked by a red pen, then the two ends are repeatedly and symmetrically found by a dot-dash line from the marking position, the continuous size chain is 160mm, 260mm, 340mm and 260mm is marked by the red pen at the corresponding position, the pre-winding end marking point is used as the central line, winding imine adhesive tapes between two 160 mark points, winding 70mm imine adhesive tapes on the other side of the 160 mark points, winding 70mm imine adhesive tapes on the two ends of the 260 mark points, winding 70mm imine adhesive tapes on the two ends of the 340mm mark points, winding 70mm imine adhesive tapes on the other ends of the 260 mark points towards one end of a central line, placing a limiting climbing layer positioning block 4, fixing one end of the limiting block 25mm away from the central line by using imine adhesive tapes, fixing the climbing layer positioning block 4 firmly by using imine adhesive tapes, corresponding a pre-winding length mark line with the central line of a winding mould, attaching an inner turn line to a winding backboard 1, pulling an outer turn line outwards, staggering a line width, knocking the line by using a cushion block, flattening the line with the aluminium mould, placing a wooden pressing block 5, clamping and clamping the winding initial position by adopting two F-shaped quick clamps 6, wherein the cushion block is required to be added when knocking the aluminium line, and the aluminium piece is forbidden to be directly knocked by using a metal piece; after the wire is bent, a rubber hammer is used for knocking to enable the aluminum wire to be flat, the aluminum wire is flatly attached to a winding die, and the inner turn wire is tightly attached to the winding backboard 1; turning on a tension button, stepping a switch, starting to wind a first layer of coil by anticlockwise rotation of equipment, starting to level the wire from a round corner by using a knocking base plate after every 90 degrees of rotation, knocking the upper surface of the wire, tightly attaching the wire to an R angle, transversely placing the knocking base plate when the straight line section is level, increasing the contact surface with the wire, beating the upper end of the base plate by using a rubber hammer, sequentially knocking from left to right, pushing the gap between the wire and an inner die to one side of the wire-outgoing disc, loosening and taking off two F-shaped quick clamps 6 and a wood cushion block at the initial position after 270 degrees of rotation of the first ring, rotating for 90 degrees again, jumping the wire to a second layer, winding anticlockwise, and enabling the knocking direction to be from left to right when the wire is leveled, winding of the first ring, and ensuring the wire to be tightly attached to the inner side of an aluminum die; the first winding step of the inner layer is repeated, the F-shaped quick clamps 6 and the wood cushion blocks of the line reaching surface are loosened and taken off in advance, the line is knocked by a knocking base plate to cling to one circle of line, the line is leveled from the R angle, the winding circle number is increased from left to right, the coil width direction needs to be knocked and leveled, the width direction is guaranteed to cling to the winding backboard 1 until the preset number of turns is wound, the coil layer is increased, in order to increase the clamping stability, an epoxy plate with small thickness can be adopted as a clamping plate, the two F-shaped quick clamps 6 are clamped at the initial position in the winding process, only one F-shaped quick clamp 6 is arranged at the other three straight line sections, the whole width is knocked in the width direction, the whole width is not leveled by a single line, and otherwise concave bending deformation easily occurs in the width direction; after the number of winding turns is reached, a rubber pad is placed, the F-shaped quick clamp 6 is clamped, an imine adhesive tape is used for winding and binding the coil, the measuring tape is used for detecting the thickness of the coil, the required number of turns is guaranteed to be reached, when the coil is bound, the F-shaped quick clamp 6 is clamped, the binding holes are offset, the imine adhesive tape is prevented from penetrating through an aluminum die notch, the coil is formed to be 75mm thick, and 12 turns of wires are combined for each layer of the coil; winding to reach the required number of turns, detecting the thickness of the wire to reach the requirement, cutting the wire from a main wire spool, wherein the cutting starting point is the central line of a winding mould, the cutting length of a 12-turn coil from the central line is 1380mm, the cutting length of an 11-turn coil from the central line is 980mm, winding the redundant wire head to the outer side of the coil after cutting, wrapping the head by using an adhesive tape, detaching the pre-winding disc from a square shaft of a winding machine, installing the pre-winding disc on an auxiliary winding frame, and preparing to wind a second-layer coil; the outer turn coil is knocked by the cushion block, the outer edge of the wire is flush with the aluminum die, a wood cushion block is placed, the wire is clamped by using two F-shaped quick clamps 6, the winding step of the first layer of coil is repeated, the winding of the second layer of coil rotates clockwise, and the knocking direction of the cushion block is from right to left; two groups of zero magnetic flux coils are combined, the upper coil is a 12-turn coil, the lower coil is an 11-turn coil, the two groups of coils are combined into a whole, the middle is fixed by two F-shaped quick clamps 6, the 12-turn coil is arranged on the upper part, and the 11-turn coil is arranged on the lower part; the assembled coils are put into a wooden tray together, and 3F-shaped quick clamps 6 are used for fixing the coils on two right-angle sides of the wooden tray; winding the extension part of the 12-turn coil on the outer side of the 11-turn coil, fixing the extension part by using an F-shaped quick clamp 6, marking the position of a wire outlet elbow by using a steel plate ruler, bending the wire head to the position of the marked wire by using a wire bending tool, marking the reserved length of the wire head by using a red pen, cutting off the redundant wire head by using a high-force shear, tightly winding the extension part of the 12-turn coil on the outer side of the 11-turn coil, fixing the R-angle by using the F-shaped quick clamp 6 at the same time, tightly winding the extension part of the 12-turn coil on the outer side of the 11-turn coil at the same time, and fixing the R-angle by using the F-shaped quick clamp 6 at the same time; reserving the length of the wire ends by 100mm, cutting the insulating layer by a blade with the front end of 70mm, stripping the insulating layer, leveling the two groups of wire ends by a rubber hammer, enabling the surfaces of the two groups of wire ends to be clung, and binding and fixing the two groups of wire ends by an imine adhesive tape; the combined coil is placed into an extrusion shaping tool, the peripheral sliding blocks 7 are adjusted, the positions of the sliding blocks 7 are adjusted to the maximum size position when the combined coil is placed into the coil, the coil is prevented from being damaged by collision, the combined coil is extruded and shaped to the required size, and the combined coil is measured by a vernier caliper, so that the size is 880 x 480.
The invention is not limited to the above embodiments, and based on the technical solution disclosed in the invention, a person skilled in the art may make some substitutions and modifications to some technical features thereof without creative effort according to the technical content disclosed, and these substitutions and modifications are all within the protection scope of the invention.
Claims (1)
1. The production process for the zero-flux coil winding operation comprises a production process and is characterized by comprising the following steps of:
step one: the winding backboard (1) and the aluminum winding die (2) are sequentially installed, so that the winding backboard (1) and the aluminum winding die (2) are completely and tightly attached, the square limiting clamping plate (3) is installed, the initial center lines of the winding backboard (1) and the aluminum winding die (2) are checked, and the overlapping of the initial center lines of the winding backboard (1) and the aluminum winding die (2) is ensured;
step two: installing a pre-winding wood disc, pulling out wire heads from a main wire disc, inserting a bayonet of the pre-winding wood disc, measuring by using a tape measure, pre-winding 18 meters of 12 turns of coils, pre-winding 17 meters of 11 turns of coils, and marking after the pre-winding is finished;
step three: when the pre-winding length is reached, marking the corresponding position by using a red pen, and then repeatedly and symmetrically finding a chain line from the marking position to two ends respectively, wherein the continuous size chain is 160mm, 260mm, 340mm and 260mm, and the corresponding position is marked by using the red pen;
step four: taking the pre-winding end mark points as central lines, winding imine adhesive tapes between the two 160 mark points, winding 70mm imine adhesive tapes on the other side of the 160 mark points, winding 70mm imine adhesive tapes on the two ends of the 260 mark points, winding 70mm imine adhesive tapes on the two ends of the 340mm mark points, winding 70mm imine adhesive tapes on one end of the central line, and winding 200mm imine adhesive tapes on the other end of the central line;
step five: placing a limiting climbing layer positioning block (4), wherein one end of the limiting block is 25mm away from the central line, and adhering and fixing the limiting block by using an imine adhesive tape;
step six: the method comprises the steps that a pre-winding length marking line corresponds to the center line of a winding mold, an inner turn line is tightly attached to a winding backboard (1), an outer turn line is pulled outwards, a line width is staggered, a cushion block is used for knocking the line, the line is flatly attached to an aluminum mold, a wooden pressing block (5) is placed, and two F-shaped quick clamps (6) are used for clamping and clamping at the winding initial position;
step seven: after the wire is bent, a rubber hammer is used for knocking to enable the aluminum wire to be flat, the aluminum wire is flatly attached to a winding die, and the inner turn wire is tightly attached to a winding backboard (1);
step eight: turning on a tension button, turning on a foot switch, starting to wind a first layer of coil by anticlockwise rotation of equipment, leveling the wire from a round corner by using a knocking base plate after every 90 degrees of rotation, knocking the upper surface of the wire to enable the wire to be tightly attached to an R angle, transversely placing the knocking base plate when the straight line section is leveled, increasing the contact surface with the wire, knocking the upper end of the base plate by using a rubber hammer, sequentially knocking from left to right, pushing the gap between the wire and an inner die to one side of the wire outgoing disc, loosening and taking off two F-shaped quick clamps (6) and a wood cushion block at the initial position after 270 degrees of rotation of the first circle, and then turning the wire to a second layer by 90 degrees;
step nine: repeating the first winding step of the inner layer, loosening and taking off the F-shaped quick clamp (6) and the wood cushion block on the surface in advance, beating the wire by using a beating base plate to cling to a circle of wire, starting to level the wire from the R angle, and sequentially from left to right, wherein the coil width direction needs to be beaten and leveled along with the increase of winding number, so as to ensure that the width direction clings to the winding backboard (1) until the preset number of turns is wound;
step ten: winding to reach the required number of turns, detecting the thickness of the wire to reach the requirement, cutting the wire from a main wire spool, wherein the cutting starting point is the central line of a winding mould, the cutting length of a 12-turn coil from the central line is 1380mm, the cutting length of an 11-turn coil from the central line is 980mm, winding the redundant wire head to the outer side of the coil after cutting, wrapping the head by using an adhesive tape, detaching the pre-winding disc from a square shaft of a winding machine, installing the pre-winding disc on an auxiliary winding frame, and preparing to wind a second-layer coil;
step eleven: beating the outer turn coil by using a cushion block, enabling the outer edge of the wire to be flush with an aluminum die, placing a wood cushion block, clamping by using two F-shaped quick clamps (6), and repeating the winding step of the first layer coil;
step twelve: two groups of zero magnetic flux coils are combined, the upper coil is a 12-turn coil, the lower coil is an 11-turn coil, the two groups of coils are combined into a whole, and the middle is fixed by two F-shaped quick clamps (6);
step thirteen: the assembled coils are put into a wooden tray together, and 3F-shaped quick clamps (6) are used for fixing the coils on two right-angle sides of the wooden tray;
step fourteen: winding the extension part of the 12-turn coil on the outer side of the 11-turn coil, fixing the extension part by using an F-shaped quick clamp (6), marking the position of an outgoing line elbow by using a steel plate ruler for marking, bending the wire head to the position of a marked wire by using a wire bending tool, marking the reserved length of the wire head by using a red pen, cutting off the redundant wire head by using a high-force shear, tightly winding the extension part of the 12-turn coil on the outer side of the 11-turn coil, and fixing the R-angle by using the F-shaped quick clamp (6) at the same time;
fifteen steps: reserving the length of the wire ends by 100mm, cutting the insulating layer by a blade with the front end of 70mm, stripping the insulating layer, leveling the two groups of wire ends by a rubber hammer, enabling the surfaces of the two groups of wire ends to be clung, and binding and fixing the two groups of wire ends by an imine adhesive tape;
step sixteen: the combined coil is placed into an extrusion shaping tool, the peripheral sliding blocks (7) are adjusted, the positions of the sliding blocks (7) are adjusted to the maximum size position when the combined coil is placed into the coil, the coil is prevented from being damaged, the combined coil is extruded and shaped to the required size, and the size is required to be 880 x 480 by using a vernier caliper for measurement.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311555827.4A CN117393313A (en) | 2023-11-21 | 2023-11-21 | Zero-flux coil winding operation production process |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311555827.4A CN117393313A (en) | 2023-11-21 | 2023-11-21 | Zero-flux coil winding operation production process |
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| CN117393313A true CN117393313A (en) | 2024-01-12 |
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| CN202311555827.4A Pending CN117393313A (en) | 2023-11-21 | 2023-11-21 | Zero-flux coil winding operation production process |
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