EP3855462B1 - Device and method for coiling ring cores without cartridges - Google Patents

Device and method for coiling ring cores without cartridges Download PDF

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Publication number
EP3855462B1
EP3855462B1 EP20152958.3A EP20152958A EP3855462B1 EP 3855462 B1 EP3855462 B1 EP 3855462B1 EP 20152958 A EP20152958 A EP 20152958A EP 3855462 B1 EP3855462 B1 EP 3855462B1
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EP
European Patent Office
Prior art keywords
winding
wire
toroidal core
plane
toroidal
Prior art date
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Application number
EP20152958.3A
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German (de)
French (fr)
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EP3855462A1 (en
EP3855462C0 (en
EP3855462B9 (en
Inventor
Alois Hofer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ruff GmbH
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Ruff GmbH
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Publication date
Priority to EP20152958.3A priority Critical patent/EP3855462B9/en
Application filed by Ruff GmbH filed Critical Ruff GmbH
Priority to US17/794,593 priority patent/US20230066596A1/en
Priority to CN202180010788.2A priority patent/CN115053307A/en
Priority to BR112022014276A priority patent/BR112022014276A2/en
Priority to PCT/EP2021/051214 priority patent/WO2021148474A1/en
Publication of EP3855462A1 publication Critical patent/EP3855462A1/en
Application granted granted Critical
Publication of EP3855462C0 publication Critical patent/EP3855462C0/en
Publication of EP3855462B1 publication Critical patent/EP3855462B1/en
Publication of EP3855462B9 publication Critical patent/EP3855462B9/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus 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
    • H01F41/02Apparatus 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
    • H01F41/04Apparatus 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
    • H01F41/06Coil winding
    • H01F41/08Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores

Definitions

  • the invention relates to a device and a method for the magazine-free winding of toroidal cores that can be guided in a toroidal core holder with a wire comprising several wire sections.
  • a toroidal core coil winding device with a toroidal core holder and an annular magazine guided through the toroidal core opening with elements used for wire guidance and wire magazine storage is, for example, from DE 101 53 896 A1 known.
  • the disadvantage of this known device is that the ring-shaped magazine has to be guided through the ring core for magazine storage and winding and thus ring cores with a small diameter or tube cores through which the magazine cannot be guided due to the spatial requirements of the magazine cannot or cannot be completely wound when winding with thicker wires.
  • Another toroidal core winding device with a toroidal core holder and a magazine-free wire guide is, for example, from the EP 2 953 149 B1 known.
  • the disadvantage of this known device is that the winding quality can be reduced due to the wire being temporarily uncontrolled during operation and the accuracy of the wire layers on the toroidal core without crossings cannot always be guaranteed.
  • the present invention is therefore based on the object of creating a device for the magazine-free winding of toroidal cores and a corresponding winding method, which enable automated and magazine-free winding of toroidal cores with, in particular, a comparatively small toroidal core diameter and of tube cores with a very small diameter.
  • the device should be simple and robust and can be produced inexpensively. Magazineless winding is understood to mean that an annular magazine does not have to be guided through the toroidal core opening, as in the prior art.
  • document US 2003/038204 A1 discloses an automatic toroidal winding device for winding toroidal coils by winding wire in a spiral onto a toroidal core.
  • document DE 101 50 818 A1 discloses a winding or bandaging device for addition to a toroidal core coil winding device, which has an annular magazine designed for wire or tape guidance and magazine storage.
  • US4 884 758 A discloses a device with a toroidal core holder for winding toroidal cores that can be guided in the toroidal core holder with a wire comprising several wire sections.
  • the invention provides a device with a toroidal core holder for winding toroidal cores that can be guided in the toroidal core holder with a wire comprising several wire sections, the toroidal core holder driving a toroidal core to be wound and the wire preferably being aligned perpendicular to one another.
  • the device further comprises a substantially circular needle ring arranged in a winding plane essentially parallel to the wire, which is rotatably mounted and can be positioned relative to the toroidal core holder in such a way that the needle ring passes through and around a wire section located in the winding plane during operation in the Toroidal core holder winds guided toroidal core.
  • the needle ring further comprises a deflection roller which is rotatably mounted on the needle ring in a first recess in the winding plane and is designed to wind the wire section located in the winding plane through and around the toroidal core during operation; and a baffle, which is arranged in a second recess in the winding plane adjacent to the first recess on the needle ring and is designed to guide the wire to be wound during operation via a guide groove between the winding plane and a magazine level arranged essentially parallel to the winding plane.
  • the device further comprises a plurality of magazining elements arranged in the magazining level, which are mounted in a stationary and rotatable manner and are designed to magazining wire sections located in the magazining level.
  • a method for winding a toroidal core that can be guided in a toroidal core holder with a wire comprising several wire sections without a magazine.
  • the method includes the rotation of a needle ring comprising a baffle and a deflection roller through the ring core and also the following steps: guiding a wire section located in a magazine level of the wire magazined on several magazine elements from magazine elements arranged in the magazine level via a guide groove of the baffle onto the deflection roller, which is arranged in a winding plane arranged essentially parallel to the magazining plane; Guiding the wire section located in the winding plane around the deflection roller towards the toroidal core; Winding the toroidal core with the wire section located in the winding plane; and return an unwound wire section located in the winding plane via the deflection roller through the guide groove onto the several magazining elements in the magazining plane.
  • the magazining takes place via the magazining elements arranged in the magazining plane, in that the wire sections located in the magazining plane are magazined onto the magazining elements. Since a predetermined length of wire from a wire supply is simultaneously wound through and around the toroidal core and stored on the magazine elements, the cycle time for winding is reduced comparatively. Because of the use of the magazine elements, which are not guided through the ring core during magazine storage and winding, and the associated lack of a conventional magazine for wire storage, at the end of winding only a wire section located in the winding plane is guided through the ring core, so that Ring cores with a very small remaining hole diameter (inner diameter of the wound ring core with wound wire layers at the end of winding) can also be wound. Furthermore, toroidal cores with small inner diameters or thicker wires can be wound than is possible with conventional toroidal core winding machines.
  • the device according to the invention is of simple construction since the annular magazine can be dispensed with. Due to the relatively simple structure, the device is also robust and inexpensive to manufacture.
  • the method according to the invention thus allows automated and magazine-free winding of toroidal cores with a small inner diameter or tube cores or other core geometries that cannot be wound with conventional toroidal core (coil) winding devices with a magazine.
  • the invention is simple in structure, as it is based on transport rollers, a wire ejector and a wire tensioner can be dispensed with. Due to the relatively simple structure, the device is also robust and inexpensive to manufacture.
  • the method according to the invention thus allows automated and magazine-free winding of toroidal cores with a small inner diameter or tubular cores or other core geometries that cannot be wound with conventional toroidal core winding devices with several wire sections magazined in the winding plane.
  • an interruption interrupts the substantially circular shape of the needle ring in an area so that the ring core can be positioned in the circumference of the needle ring or the needle ring in a position intended for winding the ring core, in which the needle ring is arranged so that it can be rotated by the toroidal core.
  • the needle ring can leave this position again and the toroidal core can be removed from the toroidal core holder.
  • the needle ring comprises a toothed ring which is arranged in a drive plane which is arranged essentially parallel to the winding plane and is designed to drive the needle ring in rotation.
  • the ring gear has teeth through which it is rotationally driven by an external drive unit. The rotational movement of the gear ring is transferred to the needle ring so that the toroidal core can be wound. This increases process control and simplifies the handling of the device.
  • the needle ring is designed to simultaneously wind the wire section located in the winding plane during operation through and around the toroidal core guided in the toroidal core holder and to magazine the wire section located in the magazining plane onto the plurality of magazining elements.
  • the wire is initially introduced into the device from a wire supply until a predetermined length of wire is supplied.
  • the predetermined length of wire from the wire supply is simultaneously wound through and around the toroidal core and magazined onto the magazine elements located in the magazine level. If the predetermined length of wire is supplied from the wire supply, the wire is separated from the wire supply so that no further wire is supplied from the wire supply and the wire sections located in the winding plane are wound through and around the toroidal core. This allows the amount of residual wire that cannot be wound on the toroid to be minimized and allows for easy automation of the process.
  • the deflection roller is set up to centrally wind the wire section located in the winding plane through and around the toroidal core.
  • the quality of the wound toroidal cores can be increased by winding the wire turns perpendicularly onto toroidal cores with a substantially circular geometry via the winding process.
  • this aspect offers more space within the toroidal core during winding. This enables a lateral relative movement between the toroidal core and the needle ring, for example to bring toroidal cores with non-circular geometry into a central position relative to the needle ring.
  • the device further comprises at least one wire brake, wherein the at least one wire brake is designed to brake the wire section located in the magazine level at intervals by pressing it against at least one of the plurality of magazine elements and to tighten the wire during operation.
  • the at least one wire brake is designed to brake the wire section located in the magazine level at intervals by pressing it against at least one of the plurality of magazine elements and to tighten the wire during operation.
  • the plurality of magazine elements are designed as rollers which are rotationally driven at intervals in an interaction with the at least one wire brake.
  • the magazine elements are mounted on a side facing away from the needle ring and closed off by surrounding areas.
  • means are provided on a side of the magazine elements facing the needle ring to prevent the elements located in the magazine level from accidentally falling down To avoid wire sections from the magazine elements during winding. These means are preferably a circumferential bevel.
  • the wire section located in the magazine level In an area of the orbit of the needle ring, which the deflection roller with the wire section located in the winding plane has passed within one revolution, the wire section located in the magazine level is driven via the rollers in the direction of rotation of the needle ring and is not braked via the at least one wire brake. In an area of the orbit of the needle ring that the deflection roller with the wire section located in the winding plane has not yet passed within one rotation, the wire section located in the magazine level is not driven via the rollers in the direction of rotation of the needle ring and is braked via the at least one wire brake. This allows the load on the wire to be kept constant and the risk of breakage is reduced. This also prevents the wire from moving loosely in the system during winding, which can increase the quality of the winding.
  • the device 1000 for magazine-free winding of toroidal cores 2000 preferably has a toroidal core holder (not shown) in which the toroidal core 2000 to be wound is held and rotated during winding.
  • the toroidal core holder is formed by three pressure rollers (not shown), which are preferably each arranged at an angle of 120° to one another around the toroidal core 2000 and press against the toroidal core 2000 from the outside and thus hold it in the desired position. At least one of the pressure rollers simultaneously drives the toroidal core 2000 and thus sets it in the desired rotation in order to wind the turns around the toroidal core 2000 at a desired distance.
  • the device 1000 for magazine-free winding of toroidal cores 2000 has several magazine elements 1210, 1220, 1230, 1240 arranged in the magazine level 4200, which are mounted in a stationary and rotatable manner and are set up to magazine wire sections 3200 located in the magazine level 4200.
  • the axis of rotation of the toroidal core 2000 preferably lies essentially in the winding plane 4100, and the axes of rotation of the toroidal core 2000 and the magazine elements 1210, 1220, 1230, 1240 are preferably arranged essentially perpendicular to one another.
  • the magazine elements 1210, 1220, 1230, 1240 are arranged evenly distributed along the orbit of the needle ring 1100.
  • the Indian Wire section 3200 located on the magazine level 4200 is magazined onto the magazine elements 1210, 1220, 1230, 1240 and is removed from it as needed during winding.
  • the number of magazine elements 1210, 1220, 1230, 1240 is not limited, but embodiments with at least four magazine elements 1210, 1220, 1230, 1240 are preferred.
  • the toroidal core 2000 is wound by the needle ring 1100 with the deflection roller 1111 with the wire section 3100 located in the winding plane 4100. Due to the rotation of the needle ring 1100 and the deflection roller 1111, a wire section 3200 located in the magazine level 4200 of the wire 3000 magazined onto the several magazine elements 1210, 1220, 1230, 1240 is removed from the magazine elements 1210, 1220, 1230, 1240 via the guide groove 1121 of the ski kane 1122 guided onto the deflection roller 1111. The wire section 3100 located in the winding level 4100 is then guided around the deflection roller 1111 to the toroidal core 2000 and wound around the toroidal core 2000.
  • the unwound wire section 3100 located in the winding level 4100 is returned via the deflection roller 1111 through the guide groove 1121 to the several magazine elements 1210, 1220, 1230, 1240 in the magazine level 4200 .
  • the amount of wire 3000 is reduced, i.e. the wire sections 3100 located in the winding level 4100 and the wire sections 3200 located in the magazine level 4200, which are guided through the toroidal core 2000. Therefore, in particular, toroidal cores 2000 can also be wound, the remaining hole diameters of which (inner diameter of the wound toroidal core 2000 with wound wire layers as the winding progresses) become small as the winding progresses.
  • the not yet wound wire section 3200 located in the magazine level 4200 is braked at intervals by the at least one wire brake 1510, 1520, 1530, 1540 by pressing it against at least one of the several magazine elements 1210, 1220, 1230, 1240 and thus tightened during operation.
  • the multiple magazine elements 1210, 1220, 1230, 1240 are according to one Embodiment designed as rollers, which are rotationally driven at intervals in interaction with the at least one wire brake 1510, 1520, 1530, 1540.
  • the magazine elements 1210, 1220, 1230, 1240 are mounted on a side facing away from the needle ring 1100 and are closed off by surrounding areas.
  • means are provided on a side of the magazine elements 1210, 1220, 1230, 1240 facing the needle ring 1100 to prevent the wire sections 3200 located in the magazine level 4200 from accidentally falling from the magazine elements 1210, 1220, 1230, 1240 during winding to avoid.
  • the means are as in Fig. 2 shown circumferential chamfer 1211, 1221, 1231, 1241. As in Fig.
  • the wire section 3200 located in the magazine level 4200 is driven via the rollers in the direction of rotation of the needle ring 1100 and not braked via the at least one wire brake 1510, 1520, 1530, 1540.
  • the wire section 3200 located in the magazine level 4200 is not driven via the rollers in the direction of rotation of the needle ring 1100 and braked via the at least one wire brake 1510, 1520, 1530, 1540.
  • This allows the load on the wire 3000 to be kept constant and the risk of it breaking off can be reduced. Furthermore, this prevents the wire 3000 from moving loosely in the system during winding, which can increase the quality of the winding.
  • the method 6000 for magazine-free winding of toroidal cores 2000 can be as follows with reference to Fig. 4 to 6 to be discribed.
  • the toroidal core 2000 is held in the toroidal core holder and rotates during winding.
  • a wire end 3300 from the wire supply is guided around the deflection roller 1111 and past the toroidal core 2000, as in Fig. 4 and 5 shown.
  • the wire end 3300 guided past the toroidal core 2000 is fixed (shown as a cross) and the needle ring 1100 wraps a first turn around the toroidal core 2000.
  • the first turns now fix the wire 3000 during further winding and the needle ring 1100 can wind further turns without external fixation.
  • a predetermined length of wire 3000 is introduced from the wire supply into device 1000.
  • the predetermined length of wire 3000 from the wire supply is as in Figure 5 shown, thus simultaneously wound through and around the toroidal core 2000 and magazined onto the magazine elements 1210, 1220, 1230, 1240.
  • the wire 3000 is completely inserted into the device 1000 when the predetermined length of the wire 3000 is magazined onto the magazine elements 1210, 1220, 1230, 1240 located in the magazine level 4200.
  • Fig. 6 shows a flowchart 6000 of a method for magazine-free winding of toroidal cores according to an embodiment of the present invention.
  • the deflection roller 1111 is preferably arranged in the winding plane 4100, which is arranged essentially parallel to the magazine level 4200.
  • the wire section 3100 located in the winding plane 4100 is guided around the deflection roller 1111 towards the toroidal core 2000.
  • the toroidal core 2000 is wound with the wire section 3100 located in the winding plane 4100.
  • the toroidal core 2000 is held by the toroidal core holder and rotates during the winding process.
  • an unwound wire section 3100 located in the winding level 4100 is moved over the Deflection roller 1111 is returned through the guide groove 1121 to the several magazine elements 1210, 1220, 1230, 1240 in the magazine level 4200.
  • toroidal core also includes tubular cores or cores with a special opening geometry and refers in particular to toroidal cores with a small inner diameter or cores with an angled opening geometry as well as tubular cores which, according to their dimensions, cannot be wound with a conventional toroidal core winding device because the magazine is due to of the space required for the magazine cannot be guided through the toroidal core opening.
  • the embodiments described here are also suitable for winding other toroidal cores or cores with different openings and also those with larger inner diameters and allow simple and convenient winding.
  • wire also includes all other materials with which toroidal cores or similar objects can be wound according to the invention.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)

Description

Die Erfindung betrifft eine Vorrichtung und ein Verfahren zum magazinlosen Bewickeln von in einer Ringkernhalterung führbaren Ringkernen mit einem mehrere Drahtabschnitte umfassenden Draht.The invention relates to a device and a method for the magazine-free winding of toroidal cores that can be guided in a toroidal core holder with a wire comprising several wire sections.

Eine Ringkernspulen-Wickelvorrichtung mit einer Ringkernhalterung und einem durch die Ringkernöffnung geführten ringförmigen Magazin mit zur Drahtführung und Drahtmagazinierung dienenden Elementen ist beispielsweise aus der DE 101 53 896 A1 bekannt. Nachteilig wirkt sich bei dieser bekannten Vorrichtung aus, dass das ringförmige Magazin zum Magazinieren und Bewickeln durch den Ringkern geführt werden muss und somit Ringkerne mit kleinem Durchmesser oder Rohrkerne, durch die das Magazin wegen der räumlichen Erfordernisse des Magazins nicht geführt werden kann, nicht bzw. bei der Bewicklung mit dickeren Drähten nicht vollständig bewickelt werden können.A toroidal core coil winding device with a toroidal core holder and an annular magazine guided through the toroidal core opening with elements used for wire guidance and wire magazine storage is, for example, from DE 101 53 896 A1 known. The disadvantage of this known device is that the ring-shaped magazine has to be guided through the ring core for magazine storage and winding and thus ring cores with a small diameter or tube cores through which the magazine cannot be guided due to the spatial requirements of the magazine cannot or cannot be completely wound when winding with thicker wires.

Eine weitere Ringkernen-Wickelvorrichtung mit einer Ringkernhalterung und einer magazinlosen Drahtführung ist beispielsweise aus der EP 2 953 149 B1 bekannt. Nachteilig wirkt sich bei dieser bekannten Vorrichtung aus, dass die Wickelqualität aufgrund des im Betrieb zeitweise unkontrollierten Drahtes vermindert sein kann und eine Genauigkeit der Drahtlagen auf dem Ringkern ohne Kreuzungen nicht immer gewährleistet werden kann.Another toroidal core winding device with a toroidal core holder and a magazine-free wire guide is, for example, from the EP 2 953 149 B1 known. The disadvantage of this known device is that the winding quality can be reduced due to the wire being temporarily uncontrolled during operation and the accuracy of the wire layers on the toroidal core without crossings cannot always be guaranteed.

<BESCHREIBUNGSSEITE 1A HIER EINFÜGEN><INSERT DESCRIPTION PAGE 1A HERE>

Der vorliegenden Erfindung liegt daher die Aufgabe zugrunde, eine Vorrichtung zum magazinlosen Bewickeln von Ringkernen sowie ein entsprechendes Wickelverfahren zu schaffen, die ein automatisiertes und magazinloses Bewickeln von Ringkernen mit insbesondere vergleichsweise kleinem Ringkerndurchmesser sowie von Rohrkernen mit sehr kleinem Durchmesser ermöglichen. Zusätzlich soll die Vorrichtung einfach und robust aufgebaut und kostengünstig herstellbar sein. Als magazinloses Wickeln wird dabei verstanden, dass nicht wie im Stand der Technik ein ringförmiges Magazin durch die Ringkernöffnung geführt werden muss.
Dokument US 2003/038204 A1 offenbart eine automatische Ringkernwickelvorrichtung zum Bewickeln von Ringkernspulen durch Wickeln von Draht in einer Spirale auf einen Ringkern.
Dokument DE 101 50 818 A1 offenbart eine Wickel- oder Bandagiervorrichtung zum Beistellen zu einer Ringkernspulen-Wickelvorrichtung, die ein zur Draht- bzw. Bandführung und -magazinierung ausgestaltetes ringförmiges Magazin aufweist.
The present invention is therefore based on the object of creating a device for the magazine-free winding of toroidal cores and a corresponding winding method, which enable automated and magazine-free winding of toroidal cores with, in particular, a comparatively small toroidal core diameter and of tube cores with a very small diameter. In addition, the device should be simple and robust and can be produced inexpensively. Magazineless winding is understood to mean that an annular magazine does not have to be guided through the toroidal core opening, as in the prior art.
document US 2003/038204 A1 discloses an automatic toroidal winding device for winding toroidal coils by winding wire in a spiral onto a toroidal core.
document DE 101 50 818 A1 discloses a winding or bandaging device for addition to a toroidal core coil winding device, which has an annular magazine designed for wire or tape guidance and magazine storage.

Das Dokument US4 884 758 A offenbart eine Vorrichtung mit einer Ringkernhalterung zum Bewickeln von in der Ringkernhalterung führbaren Ringkernen mit einem mehrere Drahtabschnitte umfassenden Draht.The document US4 884 758 A discloses a device with a toroidal core holder for winding toroidal cores that can be guided in the toroidal core holder with a wire comprising several wire sections.

Zur Lösung dieser Aufgabe sieht die Erfindung eine Vorrichtung mit einer Ringkernhalterung zum Bewickeln von in der Ringkernhalterung führbaren Ringkernen mit einem mehrere Drahtabschnitte umfassenden Draht vor, wobei die einen zu bewickelnden Ringkern antreibende Ringkernhalterung und der Draht vorzugsweise senkrecht zueinander ausgerichtet sind. Die Vorrichtung umfasst weiterhin einen in einer zu dem Draht im Wesentlichen parallelen Wickelebene angeordneten im Wesentlichen kreisförmigen Nadelkranz, der drehbeweglich gelagert ist und relativ zu der Ringkernhalterung so positionierbar ist, dass der Nadelkranz einen in der Wickelebene befindlichen Drahtabschnitt durch und um einen im Betrieb in der Ringkernhalterung geführten Ringkern wickelt. Der Nadelkranz umfasst ferner eine Umlenkrolle, die in einer ersten Aussparung in der Wickelebene an dem Nadelkranz drehbeweglich gelagert und dazu eingerichtet ist, den in der Wickelebene befindlichen Drahtabschnitt im Betrieb durch und um den Ringkern zu wickeln; und eine Schikane, die in einer zweiten Aussparung in der Wickelebene benachbart zu der ersten Aussparung an dem Nadelkranz angeordnet und dazu eingerichtet ist, den zu wickelnden Draht im Betrieb über eine Führungsnut zwischen der Wickelebene und einer zur Wickelebene im Wesentlichen parallel angeordneten Magazinierungsebene zu führen. Die Vorrichtung umfasst ferner mehrere in der Magazinierungsebene angeordnete Magazinierungselemente, die ortsfest und drehbeweglich gelagert und dazu eingerichtet sind, in der Magazinierungsebene befindliche Drahtabschnitte zu magazinieren.To solve this problem, the invention provides a device with a toroidal core holder for winding toroidal cores that can be guided in the toroidal core holder with a wire comprising several wire sections, the toroidal core holder driving a toroidal core to be wound and the wire preferably being aligned perpendicular to one another. The device further comprises a substantially circular needle ring arranged in a winding plane essentially parallel to the wire, which is rotatably mounted and can be positioned relative to the toroidal core holder in such a way that the needle ring passes through and around a wire section located in the winding plane during operation in the Toroidal core holder winds guided toroidal core. The needle ring further comprises a deflection roller which is rotatably mounted on the needle ring in a first recess in the winding plane and is designed to wind the wire section located in the winding plane through and around the toroidal core during operation; and a baffle, which is arranged in a second recess in the winding plane adjacent to the first recess on the needle ring and is designed to guide the wire to be wound during operation via a guide groove between the winding plane and a magazine level arranged essentially parallel to the winding plane. The device further comprises a plurality of magazining elements arranged in the magazining level, which are mounted in a stationary and rotatable manner and are designed to magazining wire sections located in the magazining level.

Zur Lösung der Aufgabe wird weiterhin ein Verfahren zum magazinlosen Bewickeln von einem in einer Ringkernhalterung führbaren Ringkern mit einem mehrere Drahtabschnitte umfassenden Draht vorgeschlagen. Das Verfahren umfasst dabei die Rotation eines eine Schikane und eine Umlenkrolle umfassenden Nadelkranzes durch den Ringkern und ferner folgende Schritte: Führen eines in einer Magazinierungsebene befindlichen Drahtabschnitts des auf mehreren Magazinierungselementen magazinierten Drahtes von in der Magazinierungsebene angeordneten Magazinierungselementen über eine Führungsnut der Schikane auf die Umlenkrolle, die in einer zu der Magazinierungsebene im Wesentlichen parallel angeordneten Wickelebene angeordnet ist; Führen des in der Wickelebene befindlichen Drahtabschnitts um die Umlenkrolle hin zu dem Ringkern; Bewickeln des Ringkerns mit dem in der Wickelebene befindlichen Drahtabschnitt; und Rückführen eines nicht gewickelten in der Wickelebene befindlichen Drahtabschnitts über die Umlenkrolle durch die Führungsnut auf die mehreren Magazinierungselemente in der Magazinierungsebene.To solve the problem, a method for winding a toroidal core that can be guided in a toroidal core holder with a wire comprising several wire sections without a magazine is also proposed. The method includes the rotation of a needle ring comprising a baffle and a deflection roller through the ring core and also the following steps: guiding a wire section located in a magazine level of the wire magazined on several magazine elements from magazine elements arranged in the magazine level via a guide groove of the baffle onto the deflection roller, which is arranged in a winding plane arranged essentially parallel to the magazining plane; Guiding the wire section located in the winding plane around the deflection roller towards the toroidal core; Winding the toroidal core with the wire section located in the winding plane; and return an unwound wire section located in the winding plane via the deflection roller through the guide groove onto the several magazining elements in the magazining plane.

Die Magazinierung erfolgt damit erfindungsgemäß über die in der Magazinierungsebene angeordneten Magazinierungselemente, indem die in der Magazinierungsebene befindlichen Drahtabschnitte auf die Magazinierungselemente magaziniert werden. Da eine vorbestimmte Länge des Drahtes aus einem Drahtvorrat gleichzeitig durch und um den Ringkern gewickelt und auf die Magazinierungselemente magaziniert wird, verringert sich die Zykluszeit des Bewickelns vergleichsweise. Da durch den Einsatz der Magazinierungselemente, die beim Magazinieren und Wickeln nicht durch den Ringkern geführt werden, und den damit verbundenen Verzicht auf ein herkömmliches Magazin zur Drahtbevorratung, wird am Ende des Bewickelns lediglich ein in der Wickelebene befindlicher Drahtabschnitt durch den Ringkern geführt, so dass auch Ringkerne mit sehr kleinem Restlochdurchmesser (Innendurchmesser des bewickelten Ringkerns mit aufgewickelten Drahtlagen am Ende des Bewickelns) bewickelt werden können. Des Weiteren können dadurch Ringkerne mit kleinen Innendurchmessern oder mit dickeren Drähten bewickelt werden als dies mit herkömmlichen Ringkernwickelmaschinen möglich ist.According to the invention, the magazining takes place via the magazining elements arranged in the magazining plane, in that the wire sections located in the magazining plane are magazined onto the magazining elements. Since a predetermined length of wire from a wire supply is simultaneously wound through and around the toroidal core and stored on the magazine elements, the cycle time for winding is reduced comparatively. Because of the use of the magazine elements, which are not guided through the ring core during magazine storage and winding, and the associated lack of a conventional magazine for wire storage, at the end of winding only a wire section located in the winding plane is guided through the ring core, so that Ring cores with a very small remaining hole diameter (inner diameter of the wound ring core with wound wire layers at the end of winding) can also be wound. Furthermore, toroidal cores with small inner diameters or thicker wires can be wound than is possible with conventional toroidal core winding machines.

Im Vergleich zu einer herkömmlichen Ringkern(spulen)-Wickelvorrichtung mit einem durch die Ringkernöffnung geführten ringförmigen Magazin ist die erfindungsgemäße Vorrichtung einfach aufgebaut, da auf das ringförmige Magazin verzichtet werden kann. Durch den relativ einfachen Aufbau ist die Vorrichtung ebenfalls robust und kostengünstig herzustellen. Das erfindungsgemäße Verfahren erlaubt somit ein automatisiertes und magazinloses Bewickeln auch von Ringkernen mit geringem Innendurchmesser oder Rohrkernen oder anderen Kerngeometrien, die mit herkömmlichen Ringkern(spulen)-Wickelvorrichtung mit Magazin nicht wickelbar sind.In comparison to a conventional toroidal core (coil) winding device with an annular magazine guided through the toroidal core opening, the device according to the invention is of simple construction since the annular magazine can be dispensed with. Due to the relatively simple structure, the device is also robust and inexpensive to manufacture. The method according to the invention thus allows automated and magazine-free winding of toroidal cores with a small inner diameter or tube cores or other core geometries that cannot be wound with conventional toroidal core (coil) winding devices with a magazine.

Im Vergleich zu herkömmlichen Ringkern-Wickelvorrichtungen mit mehreren in der Wickelebene magazinierten Drahtabschnitten ist die Erfindung einfach aufgebaut, da auf Transportrollen, einen Drahtauswerfer und einen Drahtstraffer verzichtet werden kann. Durch den relativ einfachen Aufbau ist die Vorrichtung ebenfalls robust und kostengünstig herzustellen. Das erfindungsgemäße Verfahren erlaubt somit ein automatisiertes und magazinloses Bewickeln auch von Ringkernen mit geringem Innendurchmesser oder Rohrkernen oder anderen Kerngeometrien, die mit herkömmlichen Ringkern-Wickelvorrichtungen mit mehreren in der Wickelebene magazinierten Drahtabschnitten nicht wickelbar sind.In comparison to conventional toroidal core winding devices with several wire sections stored in the winding plane, the invention is simple in structure, as it is based on transport rollers, a wire ejector and a wire tensioner can be dispensed with. Due to the relatively simple structure, the device is also robust and inexpensive to manufacture. The method according to the invention thus allows automated and magazine-free winding of toroidal cores with a small inner diameter or tubular cores or other core geometries that cannot be wound with conventional toroidal core winding devices with several wire sections magazined in the winding plane.

Gemäß einem Aspekt unterbricht eine Unterbrechung die im Wesentlichen kreisförmige Form des Nadelkranzes in einem Bereich, so dass der Ringkern in den Umfang des Nadelkranzes bzw. der Nadelkranz in eine zum Bewickeln des Ringkerns vorgesehene Position positionierbar ist, bei der der Nadelkranz so angeordnet ist, dass er durch den Ringkern rotierbar ist. Nach Beendung des Bewickelns kann der Nadelkranz diese Position wieder verlassen und der Ringkern kann aus der Ringkernhalterung entnommen werden. Dies ermöglicht ein vereinfachtes Bewickeln, eine einfache Automatisierung des Prozesses und eine Reduktion der Prozesszeit zum Bewickeln des Ringkerns.According to one aspect, an interruption interrupts the substantially circular shape of the needle ring in an area so that the ring core can be positioned in the circumference of the needle ring or the needle ring in a position intended for winding the ring core, in which the needle ring is arranged so that it can be rotated by the toroidal core. After winding has ended, the needle ring can leave this position again and the toroidal core can be removed from the toroidal core holder. This enables simplified winding, simple automation of the process and a reduction in the process time for winding the toroidal core.

Gemäß einem weiteren Aspekt umfasst der Nadelkranz einen Zahnkranz, der in einer zur Wickelebene im Wesentlichen parallel angeordneten Antriebsebene angeordnet und dazu eingerichtet ist, den Nadelkranz rotatorisch anzutreiben. Der Zahnkranz weist eine Verzahnung auf, über die er von einer externen Antriebseinheit rotatorisch angetrieben wird. Die rotatorische Bewegung des Zahnkranzes wird auf den Nadelkranz übertragen, so dass der Ringkern bewickelt werden kann. Dies erhöht die Prozessbeherrschung und vereinfacht die Handhabung der Vorrichtung.According to a further aspect, the needle ring comprises a toothed ring which is arranged in a drive plane which is arranged essentially parallel to the winding plane and is designed to drive the needle ring in rotation. The ring gear has teeth through which it is rotationally driven by an external drive unit. The rotational movement of the gear ring is transferred to the needle ring so that the toroidal core can be wound. This increases process control and simplifies the handling of the device.

Gemäß einem weiteren Aspekt ist der Nadelkranz dazu eingerichtet, den im Betrieb in der Wickelebene befindlichen Drahtabschnitt gleichzeitig durch und um den in der Ringkernhalterung geführten Ringkern zu wickeln und den in der Magazinierungsebene befindlichen Drahtabschnitt auf die mehreren Magazinierungselemente zu magazinieren. Der Draht wird zu Beginn aus einem Drahtvorrat in die Vorrichtung eingebracht, bis eine vorbestimmte Länge des Drahtes zugeführt ist. Die vorbestimmte Länge des Drahtes aus dem Drahtvorrat wird gleichzeitig durch und um den Ringkern gewickelt und auf die in der Magazinierungsebene befindlichen Magazinierungselemente magaziniert. Wenn die vorbestimmte Länge des Drahtes aus dem Drahtvorrat zugeführt ist, wird der Draht von dem Drahtvorrat getrennt, so dass kein weiterer Draht aus dem Drahtvorrat zugeführt wird und die in der Wickelebene befindlichen Drahtabschnitte durch und um den Ringkern gewickelt werden. Dadurch kann eine Menge an Restdraht, die nicht auf den Ringkern gewickelt werden kann, minimiert werden und es wird eine einfache Automatisierung des Prozesses ermöglicht.According to a further aspect, the needle ring is designed to simultaneously wind the wire section located in the winding plane during operation through and around the toroidal core guided in the toroidal core holder and to magazine the wire section located in the magazining plane onto the plurality of magazining elements. The wire is initially introduced into the device from a wire supply until a predetermined length of wire is supplied. The predetermined length of wire from the wire supply is simultaneously wound through and around the toroidal core and magazined onto the magazine elements located in the magazine level. If the predetermined length of wire is supplied from the wire supply, the wire is separated from the wire supply so that no further wire is supplied from the wire supply and the wire sections located in the winding plane are wound through and around the toroidal core. This allows the amount of residual wire that cannot be wound on the toroid to be minimized and allows for easy automation of the process.

Gemäß einem weiteren Aspekt ist die Umlenkrolle dazu eingerichtet, den in der Wickelebene befindlichen Drahtabschnitt zentrisch durch und um den Ringkern zu wickeln. Dadurch kann die Qualität der bewickelten Ringkerne erhöht werden, indem die Drahtwindungen über den Wickelprozess jeweils senkrecht auf Ringkerne mit im Wesentlichen kreisförmiger Geometrie aufgewickelt werden. Darüber hinaus bietet dieser Aspekt mehr Platz innerhalb des Ringkerns während des Bewickelns. Dies ermöglicht eine seitliche Relativbewegung zwischen dem Ringkern und dem Nadelkranz, um beispielsweise Ringkerne mit nicht-kreisförmiger Geometrie in eine zentrische Position gegenüber dem Nadelkranz zu bringen.According to a further aspect, the deflection roller is set up to centrally wind the wire section located in the winding plane through and around the toroidal core. As a result, the quality of the wound toroidal cores can be increased by winding the wire turns perpendicularly onto toroidal cores with a substantially circular geometry via the winding process. In addition, this aspect offers more space within the toroidal core during winding. This enables a lateral relative movement between the toroidal core and the needle ring, for example to bring toroidal cores with non-circular geometry into a central position relative to the needle ring.

Gemäß einem weiteren Aspekt umfasst die Vorrichtung ferner zumindest eine Drahtbremse, wobei die zumindest eine Drahtbremse dazu eingerichtet ist, den in der Magazinierungsebene befindlichen Drahtabschnitt, durch Anpressen an zumindest eines der mehreren Magazinierungselemente, intervallmäßig zu bremsen und den Draht im Betrieb zu straffen. Dadurch kann die Zugbelastung des Drahtes reguliert und die Belastung auf den Draht konstant gehalten und somit die Gefahr eines Abrisses sowie auch ein zu lockeres Aufwickeln des Drahtes auf den Ringkern vermindert werden.According to a further aspect, the device further comprises at least one wire brake, wherein the at least one wire brake is designed to brake the wire section located in the magazine level at intervals by pressing it against at least one of the plurality of magazine elements and to tighten the wire during operation. This allows the tensile load on the wire to be regulated and the load on the wire to be kept constant, thus reducing the risk of the wire breaking off and winding the wire too loosely onto the toroidal core.

Gemäß einem weiteren Aspekt sind die mehreren Magazinierungselemente als Rollen ausgeführt, die in einer Wechselwirkung mit der zumindest einen Drahtbremse intervallmäßig rotatorisch angetrieben sind. Die Magazinierungselemente sind in einer bevorzugten Ausführungsform auf einer dem Nadelkranz abgewandten Seite gelagert und durch umgebende Bereiche abgeschlossen. Ferner sind in einer bevorzugten Ausführungsform auf einer dem Nadelkranz zugewandten Seite der Magazinierungselemente Mittel vorgesehen, um ein ungewolltes Herunterfallen der in der Magazinierungsebene befindlichen Drahtabschnitte von den Magazinierungselementen während des Bewickelns zu vermeiden. Vorzugsweise handelt es sich bei diesen Mitteln um eine umlaufende Fase. In einem Bereich der Umlaufbahn des Nadelkranzes, den die Umlenkrolle mit dem in der Wickelebene befindlichen Drahtabschnitt innerhalb einer Umdrehung passiert hat, wird der in der Magazinierungsebene befindliche Drahtabschnitt über die Rollen in Drehrichtung des Nadelkranzes angetrieben und nicht über die zumindest eine Drahtbremse gebremst. In einem Bereich der Umlaufbahn des Nadelkranzes, den die Umlenkrolle mit dem in der Wickelebene befindlichen Drahtabschnitt innerhalb einer Drehung noch nicht passiert hat, wird der in der Magazinierungsebene befindliche Drahtabschnitt nicht über die Rollen in Drehrichtung des Nadelkranzes angetrieben und über die zumindest eine Drahtbremse gebremst. Dadurch kann die Belastung auf den Draht konstant gehalten und die Gefahr eines Abrisses vermindert werden. Ferner wird dadurch verhindert, dass sich der Draht während des Bewickelns lose im System bewegt, wodurch die Qualität des Bewickelns erhöht werden kann.According to a further aspect, the plurality of magazine elements are designed as rollers which are rotationally driven at intervals in an interaction with the at least one wire brake. In a preferred embodiment, the magazine elements are mounted on a side facing away from the needle ring and closed off by surrounding areas. Furthermore, in a preferred embodiment, means are provided on a side of the magazine elements facing the needle ring to prevent the elements located in the magazine level from accidentally falling down To avoid wire sections from the magazine elements during winding. These means are preferably a circumferential bevel. In an area of the orbit of the needle ring, which the deflection roller with the wire section located in the winding plane has passed within one revolution, the wire section located in the magazine level is driven via the rollers in the direction of rotation of the needle ring and is not braked via the at least one wire brake. In an area of the orbit of the needle ring that the deflection roller with the wire section located in the winding plane has not yet passed within one rotation, the wire section located in the magazine level is not driven via the rollers in the direction of rotation of the needle ring and is braked via the at least one wire brake. This allows the load on the wire to be kept constant and the risk of breakage is reduced. This also prevents the wire from moving loosely in the system during winding, which can increase the quality of the winding.

Ausführungsbeispiele der Erfindung werden nachstehend anhand der beigefügten Figuren näher erläutert. Es zeigen:

  • Fig. 1 eine rudimentäre schematische Seitenansicht einer Ausführungsform der Vorrichtung zum magazinlosen Bewickeln von Ringkernen, bei der u.a. die Ringkernhalterung und der Drahtvorrat zur Vereinfachung nicht gezeigt sind;
  • Fig. 2 eine rudimentäre schematische Vorderansicht eines Ausschnitts einer Ausführungsform der Vorrichtung zum magazinlosen Bewickeln von Ringkernen, bei der u.a. die Ringkernhalterung und der Drahtvorrat zur Vereinfachung nicht gezeigt sind;
  • Fig. 3 eine rudimentäre schematische Seitenansicht einer Ausführungsform der Vorrichtung zum magazinlosen Bewickeln von Ringkernen, bei der u.a. die Ringkernhalterung und der Drahtvorrat zur Vereinfachung nicht gezeigt sind;
  • Fig. 4 eine rudimentäre schematische Seitenansicht einer Ausführungsform der Vorrichtung zum magazinlosen Bewickeln von Ringkernen, bei der u.a. die Ringkernhalterung und der Drahtvorrat zur Vereinfachung nicht gezeigt sind;
  • Fig. 5 eine rudimentäre schematische Seitenansicht einer Ausführungsform der Vorrichtung zum magazinlosen Bewickeln von Ringkernen, bei der u.a. die Ringkernhalterung und der Drahtvorrat zur Vereinfachung nicht gezeigt sind;
  • Fig. 6 ein Ablaufdiagramm eines Verfahrens zum magazinlosen Bewickeln von Ringkernen gemäß einer Ausführungsform der vorliegenden Erfindung.
Embodiments of the invention are explained in more detail below with reference to the attached figures. Show it:
  • Fig. 1 a rudimentary schematic side view of an embodiment of the device for magazine-free winding of toroidal cores, in which, among other things, the toroidal core holder and the wire supply are not shown for simplicity;
  • Fig. 2 a rudimentary schematic front view of a section of an embodiment of the device for magazine-free winding of toroidal cores, in which, among other things, the toroidal core holder and the wire supply are not shown for simplicity;
  • Fig. 3 a rudimentary schematic side view of an embodiment of the device for magazine-free winding of toroidal cores, in which, among other things, the toroidal core holder and the wire supply are not shown for simplicity;
  • Fig. 4 a rudimentary schematic side view of an embodiment of the device for magazine-free winding of toroidal cores, in which, among other things, the toroidal core holder and the wire supply are not shown for simplicity;
  • Fig. 5 a rudimentary schematic side view of an embodiment of the device for magazine-free winding of toroidal cores, in which, among other things, the toroidal core holder and the wire supply are not shown for simplicity;
  • Fig. 6 a flowchart of a method for magazine-free winding of toroidal cores according to an embodiment of the present invention.

Die Vorrichtung 1000 zum magazinlosen Bewickeln von Ringkernen 2000 nach den Fig. 1 bis 3 weist vorzugsweise eine Ringkernhalterung (nicht dargestellt) auf, in der der zu bewickelnde Ringkern 2000 gehalten und beim Bewickeln rotiert wird. Die Ringkernhalterung ist gemäß einer Ausführungsform durch drei Andruckrollen (nicht dargestellt) ausgebildet, die bevorzugt jeweils im Winkel von 120° zueinander um den Ringkern 2000 angeordnet sind und von außen gegen den Ringkern 2000 drücken und ihn damit in der gewünschten Position halten. Zumindest eine der Andruckrollen treibt gleichzeitig den Ringkern 2000 an und versetzt ihn somit in die gewünschte Rotation, um die Windungen in einem gewünschten Abstand um den Ringkern 2000 zu wickeln.The device 1000 for magazine-free winding of toroidal cores 2000 according to Fig. 1 to 3 preferably has a toroidal core holder (not shown) in which the toroidal core 2000 to be wound is held and rotated during winding. According to one embodiment, the toroidal core holder is formed by three pressure rollers (not shown), which are preferably each arranged at an angle of 120° to one another around the toroidal core 2000 and press against the toroidal core 2000 from the outside and thus hold it in the desired position. At least one of the pressure rollers simultaneously drives the toroidal core 2000 and thus sets it in the desired rotation in order to wind the turns around the toroidal core 2000 at a desired distance.

Anstelle eines Magazins weist die Vorrichtung 1000 zum magazinlosen Bewickeln von Ringkernen 2000 mehrere in der Magazinierungsebene 4200 angeordnete Magazinierungselemente 1210, 1220, 1230, 1240 auf, die ortsfest und drehbeweglich gelagert und dazu eingerichtet sind, in der Magazinierungsebene 4200 befindliche Drahtabschnitte 3200 zu magazinieren. Die Rotationsachse des Ringkerns 2000 liegt bevorzugt im Wesentlichen in der Wickelebene 4100, und die Rotationsachsen des Ringkerns 2000 und der Magazinierungselemente 1210, 1220, 1230, 1240 sind vorzugsweise im Wesentlichen senkrecht zueinander angeordnet.Instead of a magazine, the device 1000 for magazine-free winding of toroidal cores 2000 has several magazine elements 1210, 1220, 1230, 1240 arranged in the magazine level 4200, which are mounted in a stationary and rotatable manner and are set up to magazine wire sections 3200 located in the magazine level 4200. The axis of rotation of the toroidal core 2000 preferably lies essentially in the winding plane 4100, and the axes of rotation of the toroidal core 2000 and the magazine elements 1210, 1220, 1230, 1240 are preferably arranged essentially perpendicular to one another.

Gemäß der in den Fig. 1 bis 3 dargestellten Ausführungsform sind die Magazinierungselemente 1210, 1220, 1230, 1240 entlang der Umlaufbahn des Nadelkranzes 1100 gleichmäßig verteilt angeordnet. Der in der Magazinierungsebene 4200 befindliche Drahtabschnitt 3200 ist auf die Magazinierungselemente 1210, 1220, 1230, 1240 magaziniert und wird während des Bewickelns bedarfsmäßig davon entnommen. Die Anzahl der Magazinierungselemente 1210, 1220, 1230, 1240 ist dabei nicht limitiert, bevorzugt werden jedoch Ausführungsformen mit mindestens vier Magazinierungselementen 1210, 1220, 1230, 1240.According to the in the Fig. 1 to 3 In the embodiment shown, the magazine elements 1210, 1220, 1230, 1240 are arranged evenly distributed along the orbit of the needle ring 1100. The Indian Wire section 3200 located on the magazine level 4200 is magazined onto the magazine elements 1210, 1220, 1230, 1240 and is removed from it as needed during winding. The number of magazine elements 1210, 1220, 1230, 1240 is not limited, but embodiments with at least four magazine elements 1210, 1220, 1230, 1240 are preferred.

Zum weiteren Bewickeln wird der Ringkern 2000 von dem Nadelkranz 1100 mit der Umlenkrolle 1111 mit dem in der Wickelebene 4100 befindlichen Drahtabschnitt 3100 bewickelt. Durch die Rotation des Nadelkranzes 1100 und der Umlenkrolle 1111 wird ein in der Magazinierungsebene 4200 befindlicher Drahtabschnitt 3200 des auf die mehreren Magazinierungselemente 1210, 1220, 1230, 1240 magazinierten Drahtes 3000 von den Magazinierungselementen 1210, 1220, 1230, 1240 über die Führungsnut 1121 der Schikane 1122 auf die Umlenkrolle 1111 geführt. Der in der Wickelebene 4100 befindliche Drahtabschnitt 3100 wird anschließend um die Umlenkrolle 1111 hin zu dem Ringkern 2000 geführt und um den Ringkern 2000 gewickelt. Nach dem Bewickeln des Ringkerns 2000 mit dem in der Wickelebene 4100 befindlichen Drahtabschnitt 3100 wird der nicht gewickelte in der Wickelebene 4100 befindliche Drahtabschnitt 3100 über die Umlenkrolle 1111 durch die Führungsnut 1121 auf die mehreren Magazinierungselemente 1210, 1220, 1230, 1240 in der Magazinierungsebene 4200 rückgeführt. Mit dem fortschreitenden Bewickeln des Drahtes 3000 auf den Ringkern 2000 reduziert sich die Menge an Draht 3000, d.h. die in der Wickelebene 4100 befindlichen Drahtabschnitte 3100 und die in der Magazinierungsebene 4200 befindlichen Drahtabschnitte 3200, die durch den Ringkern 2000 geführt werden. Daher können insbesondere auch Ringkerne 2000 bewickelt werden, deren Restlochdurchmesser (Innendurchmesser des bewickelten Ringkerns 2000 mit aufgewickelten Drahtlagen beim Fortschreiten des Bewickelns) im Verlauf des Bewickelns klein werden.For further winding, the toroidal core 2000 is wound by the needle ring 1100 with the deflection roller 1111 with the wire section 3100 located in the winding plane 4100. Due to the rotation of the needle ring 1100 and the deflection roller 1111, a wire section 3200 located in the magazine level 4200 of the wire 3000 magazined onto the several magazine elements 1210, 1220, 1230, 1240 is removed from the magazine elements 1210, 1220, 1230, 1240 via the guide groove 1121 of the ski kane 1122 guided onto the deflection roller 1111. The wire section 3100 located in the winding level 4100 is then guided around the deflection roller 1111 to the toroidal core 2000 and wound around the toroidal core 2000. After winding the toroidal core 2000 with the wire section 3100 located in the winding level 4100, the unwound wire section 3100 located in the winding level 4100 is returned via the deflection roller 1111 through the guide groove 1121 to the several magazine elements 1210, 1220, 1230, 1240 in the magazine level 4200 . As the wire 3000 is progressively wound onto the toroidal core 2000, the amount of wire 3000 is reduced, i.e. the wire sections 3100 located in the winding level 4100 and the wire sections 3200 located in the magazine level 4200, which are guided through the toroidal core 2000. Therefore, in particular, toroidal cores 2000 can also be wound, the remaining hole diameters of which (inner diameter of the wound toroidal core 2000 with wound wire layers as the winding progresses) become small as the winding progresses.

Der noch nicht gewickelte in der Magazinierungsebene 4200 befindliche Drahtabschnitt 3200 wird von der zumindest einen Drahtbremse 1510, 1520, 1530, 1540 durch Anpressen an zumindest eines der mehreren Magazinierungselemente 1210, 1220, 1230, 1240 intervallmäßig gebremst und somit im Betrieb gestrafft. Die mehreren Magazinierungselemente 1210, 1220, 1230, 1240 sind gemäß einer Ausführungsform als Rollen ausgeführt, die in Wechselwirkung mit der zumindest einen Drahtbremse 1510, 1520, 1530, 1540 intervallmäßig rotatorisch angetrieben sind. Die Magazinierungselemente 1210, 1220, 1230, 1240 sind in einer bevorzugten Ausführungsform auf einer dem Nadelkranz 1100 abgewandten Seite gelagert und durch umgebende Bereiche abgeschlossen. Ferner sind in einer bevorzugten Ausführungsform auf einer dem Nadelkranz 1100 zugewandten Seite der Magazinierungselemente 1210, 1220, 1230, 1240 Mittel vorgesehen, um ein ungewolltes Herunterfallen der in der Magazinierungsebene 4200 befindlichen Drahtabschnitte 3200 von den Magazinierungselementen 1210, 1220, 1230, 1240 während des Bewickelns zu vermeiden. Vorzugsweise handelt es sich bei den Mitteln um eine wie in Fig. 2 dargestellte umlaufende Fase 1211, 1221, 1231, 1241. Wie in Fig. 3 gezeigt, wird in einem Bereich der Umlaufbahn des Nadelkranzes 1100, den die Umlenkrolle 1111 mit dem in der Wickelebene 4100 befindlichen Drahtabschnitt 3100 innerhalb einer Umdrehung passiert hat, der in der Magazinierungsebene 4200 befindliche Drahtabschnitt 3200 über die Rollen in Drehrichtung des Nadelkranzes 1100 angetrieben und nicht über die zumindest eine Drahtbremse 1510, 1520, 1530, 1540 gebremst. In einem Bereich der Umlaufbahn des Nadelkranzes 1100, den die Umlenkrolle 1111 mit dem in der Wickelebene 4100 befindlichen Drahtabschnitt 3100 innerhalb einer Drehung noch nicht passiert hat, wird der in der Magazinierungsebene 4200 befindliche Drahtabschnitt 3200 nicht über die Rollen in Drehrichtung des Nadelkranzes 1100 angetrieben und über die zumindest eine Drahtbremse 1510, 1520, 1530, 1540 gebremst. Dadurch kann die Belastung auf den Draht 3000 konstant gehalten und die Gefahr eines Abrisses vermindert werden. Ferner wird dadurch verhindert, dass sich der Draht 3000 während des Bewickelns lose im System bewegt, wodurch die Qualität des Bewickelns erhöht werden kann.The not yet wound wire section 3200 located in the magazine level 4200 is braked at intervals by the at least one wire brake 1510, 1520, 1530, 1540 by pressing it against at least one of the several magazine elements 1210, 1220, 1230, 1240 and thus tightened during operation. The multiple magazine elements 1210, 1220, 1230, 1240 are according to one Embodiment designed as rollers, which are rotationally driven at intervals in interaction with the at least one wire brake 1510, 1520, 1530, 1540. In a preferred embodiment, the magazine elements 1210, 1220, 1230, 1240 are mounted on a side facing away from the needle ring 1100 and are closed off by surrounding areas. Furthermore, in a preferred embodiment, means are provided on a side of the magazine elements 1210, 1220, 1230, 1240 facing the needle ring 1100 to prevent the wire sections 3200 located in the magazine level 4200 from accidentally falling from the magazine elements 1210, 1220, 1230, 1240 during winding to avoid. Preferably the means are as in Fig. 2 shown circumferential chamfer 1211, 1221, 1231, 1241. As in Fig. 3 shown, in an area of the orbit of the needle ring 1100, which the deflection roller 1111 with the wire section 3100 located in the winding plane 4100 has passed within one revolution, the wire section 3200 located in the magazine level 4200 is driven via the rollers in the direction of rotation of the needle ring 1100 and not braked via the at least one wire brake 1510, 1520, 1530, 1540. In an area of the orbit of the needle ring 1100, which the deflection roller 1111 with the wire section 3100 located in the winding plane 4100 has not yet passed within one rotation, the wire section 3200 located in the magazine level 4200 is not driven via the rollers in the direction of rotation of the needle ring 1100 and braked via the at least one wire brake 1510, 1520, 1530, 1540. This allows the load on the wire 3000 to be kept constant and the risk of it breaking off can be reduced. Furthermore, this prevents the wire 3000 from moving loosely in the system during winding, which can increase the quality of the winding.

Gemäß einer Ausführungsform kann das Verfahren 6000 zum magazinlosen Bewickeln von Ringkernen 2000 wie nachfolgend unter Bezugnahme auf die Fig. 4 bis 6 beschrieben werden. Der Ringkern 2000 wird in der Ringkernhalterung gehalten und beim Bewickeln rotiert. Zunächst wird ein Drahtende 3300 aus dem Drahtvorrat um die Umlenkrolle 1111 und an dem Ringkern 2000 vorbei geführt, wie in Fig. 4 und 5 dargestellt. Das an dem Ringkern 2000 vorbei geführte Drahtende 3300 wird fixiert (als Kreuz dargestellt) und der Nadelkranz 1100 wickelt eine erste Windung um den Ringkern 2000. Die ersten Windungen fixieren nun den Draht 3000 während des weiteren Bewickelns und der Nadelkranz 1100 kann ohne eine externe Fixierung weitere Windungen wickeln. Nachfolgend wird eine vorbestimmte Länge des Drahtes 3000 aus dem Drahtvorrat in die Vorrichtung 1000 eingebracht. Die vorbestimmte Länge des Drahtes 3000 aus dem Drahtvorrat wird, wie in Figur 5 dargestellt, somit gleichzeitig durch und um den Ringkern 2000 gewickelt und auf die Magazinierungselemente 1210, 1220, 1230, 1240 magaziniert. Der Draht 3000 ist vollständig in die Vorrichtung 1000 eingebracht, wenn die vorbestimmte Länge des Drahtes 3000 auf die in der Magazinierungsebene 4200 befindlichen Magazinierungselemente 1210, 1220, 1230, 1240 magaziniert ist. Wenn die vorbestimmte Länge des Drahtes 3000 aus dem Drahtvorrat zugeführt und auf die Magazinierungselemente 1210, 1220, 1230, 1240 magaziniert ist, wird der Draht 3000 von dem Drahtvorrat getrennt und somit kein weiterer Draht 3000 aus dem Drahtvorrat zugeführt und der in der Wickelebene 4100 befindliche Drahtabschnitt 3100 wird weiterhin durch und um den Ringkern 2000 gewickelt, wie in Fig. 3 dargestellt. Dadurch kann eine Menge an Restdraht, die nicht auf den Ringkern 2000 gewickelt werden kann, minimiert werden und es wird damit ein automatisiertes und magazinloses Bewickeln von Ringkernen 2000 ermöglicht.According to one embodiment, the method 6000 for magazine-free winding of toroidal cores 2000 can be as follows with reference to Fig. 4 to 6 to be discribed. The toroidal core 2000 is held in the toroidal core holder and rotates during winding. First, a wire end 3300 from the wire supply is guided around the deflection roller 1111 and past the toroidal core 2000, as in Fig. 4 and 5 shown. The wire end 3300 guided past the toroidal core 2000 is fixed (shown as a cross) and the needle ring 1100 wraps a first turn around the toroidal core 2000. The first turns now fix the wire 3000 during further winding and the needle ring 1100 can wind further turns without external fixation. Subsequently, a predetermined length of wire 3000 is introduced from the wire supply into device 1000. The predetermined length of wire 3000 from the wire supply is as in Figure 5 shown, thus simultaneously wound through and around the toroidal core 2000 and magazined onto the magazine elements 1210, 1220, 1230, 1240. The wire 3000 is completely inserted into the device 1000 when the predetermined length of the wire 3000 is magazined onto the magazine elements 1210, 1220, 1230, 1240 located in the magazine level 4200. When the predetermined length of the wire 3000 is supplied from the wire supply and magazined onto the magazine elements 1210, 1220, 1230, 1240, the wire 3000 is separated from the wire supply and therefore no further wire 3000 is supplied from the wire supply and the one located in the winding level 4100 Wire section 3100 is further wound through and around toroidal core 2000, as in Fig. 3 shown. This allows the amount of residual wire that cannot be wound on the toroidal core 2000 to be minimized, thereby enabling automated and magazine-free winding of toroidal cores 2000.

Fig. 6 zeigt ein Ablaufdiagramm 6000 eines Verfahrens zum magazinlosen Bewickeln von Ringkernen gemäß einer Ausführungsform der vorliegenden Erfindung. Gemäß Schritt 6100 wird während des Wickelvorgangs der in der Magazinierungsebene 4200 befindliche Drahtabschnitt 3200 des auf den mehreren Magazinierungselementen 1210, 1220, 1230, 1240 magazinierten Drahtes von den in der Magazinierungsebene 4200 angeordneten Magazinierungselementen 1210, 1220, 1230, 1240 über eine Führungsnut 1121 der Schikane 1122 auf die Umlenkrolle 1111 geführt. Die Umlenkrolle 1111 ist dabei bevorzugt in der zu der Magazinierungsebene 4200 im Wesentlichen parallel angeordneten Wickelebene 4100 angeordnet. Gemäß einem weiteren Schritt 6200 wird der in der Wickelebene 4100 befindliche Drahtabschnitt 3100 um die Umlenkrolle 1111 hin zum Ringkern 2000 geführt. Gemäß einem weiteren Schritt 6300 wird der Ringkern 2000 mit dem in der Wickelebene 4100 befindlichen Drahtabschnitt 3100 bewickelt. Der Ringkern 2000 wird dabei von der Ringkernhalterung gehalten und während des Wickelvorgangs rotiert. Gemäß einem weiteren Schritt 6400 wird ein nicht gewickelter in der Wickelebene 4100 befindlicher Drahtabschnitt 3100 über die Umlenkrolle 1111 durch die Führungsnut 1121 auf die mehreren Magazinierungselemente 1210, 1220, 1230, 1240 in der Magazinierungsebene 4200 rückgeführt. Fig. 6 shows a flowchart 6000 of a method for magazine-free winding of toroidal cores according to an embodiment of the present invention. According to step 6100, the wire section 3200 of the wire from the magazine elements 1210, 1220, 1220, 1220, 1220, 1220, 1220, 1220, 1220, 1220, 1220, 1220, 1220, 1220, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 120, 1240 of the chicane in the Magazine level. 1122 guided onto the deflection roller 1111. The deflection roller 1111 is preferably arranged in the winding plane 4100, which is arranged essentially parallel to the magazine level 4200. According to a further step 6200, the wire section 3100 located in the winding plane 4100 is guided around the deflection roller 1111 towards the toroidal core 2000. According to a further step 6300, the toroidal core 2000 is wound with the wire section 3100 located in the winding plane 4100. The toroidal core 2000 is held by the toroidal core holder and rotates during the winding process. According to a further step 6400, an unwound wire section 3100 located in the winding level 4100 is moved over the Deflection roller 1111 is returned through the guide groove 1121 to the several magazine elements 1210, 1220, 1230, 1240 in the magazine level 4200.

Im Sinne der Erfindung schließt der Begriff Ringkern auch Rohrkerne oder Kerne mit besonderer Öffnungsgeometrie ein und betrifft insbesondere solche Ringkerne mit kleinem Innendurchmesser oder Kerne mit verwinkelter Öffnungsgeometrie sowie Rohrkerne, die gemäß ihrer Dimensionierung nicht mit herkömmlichen Ringkern-Wickelvorrichtung bewickelt werden können, da das Magazin aufgrund des für das Magazin erforderlichen Raumes nicht durch die Ringkernöffnung geführt werden kann. Die hier beschriebenen Ausführungsformen eignen sich jedoch ebenfalls zum Bewickeln von sonstigen Ringkernen oder Kernen mit sonstiger Öffnung und auch solchen mit größeren Innendurchmessern und erlauben ein einfaches und komfortables Bewickeln.For the purposes of the invention, the term toroidal core also includes tubular cores or cores with a special opening geometry and refers in particular to toroidal cores with a small inner diameter or cores with an angled opening geometry as well as tubular cores which, according to their dimensions, cannot be wound with a conventional toroidal core winding device because the magazine is due to of the space required for the magazine cannot be guided through the toroidal core opening. However, the embodiments described here are also suitable for winding other toroidal cores or cores with different openings and also those with larger inner diameters and allow simple and convenient winding.

Im Sinne der Erfindung schließt der Begriff Draht auch sämtlichen sonstigen Materialien ein, mit denen sinnvoller Weise Ringkerne oder ähnliche Gegenstände erfindungsgemäß zu bewickeln sind.In the sense of the invention, the term wire also includes all other materials with which toroidal cores or similar objects can be wound according to the invention.

Weitere vorteilhafte Ausgestaltungen und Abwandlungen ergeben sich für den Fachmann aus den hier beschriebenen Ausführungsbeispielen und werden von ihm als zur Erfindung gehörig verstanden.Further advantageous refinements and modifications arise for the person skilled in the art from the exemplary embodiments described here and are understood by him to be part of the invention.

Claims (13)

  1. Device (1000) with a toroidal core retaining element for winding toroidal cores (2000), which can be guided in the toroidal core retaining device, with a wire (3000) comprising a multiplicity of wire sections (3100, 3200), and further comprising:
    a substantially circular needle roller (1100), arranged in a winding plane (4100) substantially parallel to the wire (3000) and mounted such as to be rotatably movable and which can be positioned relative to the toroidal core retaining element in such a way that the needle roller (1100) winds a wire section (3100) located in the winding plane (4100) through and about a toroidal core (2000) guided in the toroidal core retaining element when in operation, wherein the needle roller (1100) further comprises:
    a deflecting roller (1111), which is rotationally mounted in a first recess in the winding plane (4100) at the needle roller (1100), and is designed such as to wind the wire section (3100) located in the winding plane (4100) through and about the toroidal core (2000) when in operation; characterized in that the needle roller (1100) further comprises
    a baffle plate (1122), which is arranged in a second recess in the winding plane (4100), adjacent to the first recess at the needle roller (1100), and which is designed to guide the wire (3000) which is to be wound, during operation, via a guide groove (1121) between the winding plane (4100) and a storing plane (4200) arranged substantially parallel to the winding plane (4100),
    and the device (1000) further comprises:
    a multiplicity of storing elements (1210, 1220, 1230, 1240) arranged in the storing plane (4200), which are mounted in a stationary and rotatable manner, and are designed to store the wire sections (3200) located in the storing plane (4200).
  2. Device (1000) for winding toroidal cores (2000) according to claim 1, wherein an interruption interrupts the substantially circular form of the needle roller (1100) in one region, such that the needle roller (1100) can be positioned in a position provided for the winding of the toroidal core (2000), and wherein the needle roller (1100) is arranged in such a way that it can be rotated through the toroidal core (2000).
  3. Device (1000) for winding toroidal cores (2000) according to any one of the preceding claims, wherein the needle roller (1100) comprises a toothed rim, which is arranged in a drive plane arranged substantially parallel to the winding plane (4100), and is designed to drive the needle roller (1100) rotationally.
  4. Device (1000) for winding toroidal cores (2000) according to any one of the preceding claims, wherein the needle roller (1100) is designed such as to wind the wire section (3100) located in the winding plane (4100), when in operation, simultaneously through and about the toroidal core (2000) which is being guided in the toroidal core retaining element and to store the wire section (3200) located in the storing plane (4200) onto the multiplicity of storing elements (1210, 1220, 1230, 1240).
  5. Device (1000) for winding toroidal cores (2000) according to any one of the preceding claims, wherein the deflecting roller (1111) is designed such as to wind the wire section (3100) located in the winding plane (4100) centrally through and about the toroidal core (2000).
  6. Device (1000) for winding toroidal cores (2000) according to any one of the preceding claims, further comprising at least one wire brake (1510, 1520, 1530, 1540), wherein the at least one wire brake (1510, 1520, 1530, 1540) is designed such as to brake the wire section (3200) located in the storing plane (4200) by pressing at intervals on at least one of the multiplicity of storing elements (1210, 1220, 1230, 1240), and to keep the wire (3000) taut when in operation.
  7. Device (1000) for winding toroidal cores (2000) according to claim 6, wherein the multiplicity of storing elements (1210, 1220, 1230, 1240) are rollers, which are driven in rotation at intervals in reciprocal effect with the at least one wire brake (1510, 1520, 1530, 1540).
  8. Method for winding a toroidal core (2000), which can be guided in a toroidal core retaining element, with a wire (3000) comprising a multiplicity of wire section (3100, 3200), wherein the method comprises the rotation of a needle roller (1100), comprising a baffle plate (1122) and a deflecting roller (1111), through the toroidal core (2000), and comprises the following steps:
    a. Guiding a wire section (3200), located in a storing plane (4200), of the wire (3000) stored on a multiplicity of storing elements (1210, 1220, 1230, 1240) from storing elements (1210, 1220, 1230, 1240) arranged in the storing plane (4200), via a guide groove (1121) of the baffle plate (1122), and onto the deflecting roller (1111), which is arranged in a winding plane (4100) arranged substantially parallel to the storing plane (4200),
    b. Guiding the wire section (3100) located in the winding plane (4100) about the deflecting roller (1111) as far as the toroidal core (2000);
    c. Winding the toroidal core (2000) with the wire section (3100) located in the winding plane (4100); and
    d. Guiding back a wire section (3100) located in the winding plane (4100) which has not been wound, via the deflecting roller (1111), through the guide groove (1121), and onto the multiplicity of storage elements (1210, 1220, 1230, 1240) in the storing plane (4200).
  9. Method for winding a toroidal core (2000) according to claim 8, wherein the toroidal core (2000) guided in the toroidal core retaining element rotates when in operation perpendicular to the rotation of the needle roller (1100).
  10. Method for winding a toroidal core (2000) according to any one of claims 8 or 9, wherein the wire (3000) on the storing elements (1210, 1220, 1230, 1240) is tautened at intervals by at least one wire brake (1510, 1520, 1530, 1540).
  11. Method for winding a toroidal core (2000) according to any one of claims 8 to 10, wherein the method is carried out by making use of the device (1000) for winding of toroidal cores (2000) according to any one of claims 1 to 7.
  12. Method for winding a toroidal core (2000) according to any one of claims 8 to 11, wherein, at the beginning of the method, the wire section (3100) located in the winding plane (4100) is wound simultaneously through and about the toroidal core (2000), and the quantity of wire required is stored on the multiplicity of storing elements (1210, 1220, 1230, 1240) in the storing plane (4200).
  13. Method for winding a toroidal core (2000) according to any one of claims 8 to 12, wherein the steps a. to d. are run through repeatedly, in order to wind the desired number of windings of the wire (3000) onto the toroidal core (2000).
EP20152958.3A 2020-01-21 2020-01-21 Device and method for coiling ring cores without cartridges Active EP3855462B9 (en)

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EP20152958.3A EP3855462B9 (en) 2020-01-21 2020-01-21 Device and method for coiling ring cores without cartridges
CN202180010788.2A CN115053307A (en) 2020-01-21 2021-01-20 Apparatus and method for winding toroidal cores without the use of a magazine
BR112022014276A BR112022014276A2 (en) 2020-01-21 2021-01-20 DEVICE AND METHOD FOR WINDING TOROIDAL CORES WITHOUT USING A COIL
PCT/EP2021/051214 WO2021148474A1 (en) 2020-01-21 2021-01-20 Device and method for winding toroidal cores without using a magazine
US17/794,593 US20230066596A1 (en) 2020-01-21 2021-01-20 Device and Method for Winding Toroidal Cores Without Using a Magazine

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EP20152958.3A EP3855462B9 (en) 2020-01-21 2020-01-21 Device and method for coiling ring cores without cartridges

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US4884758A (en) * 1985-02-06 1989-12-05 Kuhlman Corporation Self-loading wire winding assembly and method
US6557793B2 (en) * 2001-08-24 2003-05-06 Harmonic Drive Systems, Inc. Toroidal core winding method and automatic winding apparatus
DE10150818B4 (en) * 2001-10-15 2004-07-22 Ruff Gmbh & Co. Kg Winding or bandaging device and toroid coil winding and bandaging system
DE10153896A1 (en) 2001-11-02 2003-05-28 Herbert Ruff Gmbh & Co Kg Direct winding device for ring core coils, has magazine in contact with drive belt in parts of exterior and mounted in guide with two guide elements on both sides of magazine with gap for wire
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BR112022014276A2 (en) 2022-12-13
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US20230066596A1 (en) 2023-03-02
EP3855462B9 (en) 2024-04-03

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