SI26397A - Automated device and process of winding the wire of toroidal transformers - Google Patents

Abstract

The automated device and the process of winding the wire of toroidal transformers consists of a structure (ANS), lead-in (UV), winding ring (NO), downward-facing robot (R) with two grippers (P1), (P2), electric control, scissors (Š ), (ŠK2), grips (MO). The winding ring (NO) has grooves (U) that enable robotic winding of the wire (Ž), the joint is self-closing in the tangential direction, and open in the radial direction. by pulling the wire (Z) up to max. 15 percent of the tensile strength of the wire, disconnected. The guide (UV) has pneumatic pliers (KL) that arrest the wire (Ž), the gripper (P1) brings it to the grooves (U) around which it is wrapped, then the winding ring (NO) turns and winds the wire (Z), the relief the pulley (RŠ) relieves the force in the wire (Ž) by moving downwards. The guide (UV) is positioned at the starting point, and the scissors (Š) cut the wire (Ž). The gripper (P1) catches the end of the remaining wire (Ž) through the shape (P1.2) and pulls it out of the match with the grooves (U) and matches between the winding ring (NO) and the toothed belt (ZJ).

Description

Automated device and process of winding the wire of toroidal transformers

The subject of the invention is the technical invention of performing complete robotic mechanical manipulation of the winding wire and winding on a toroid, which is essentially a cylinder with rounded edges, without the need for a worker, in terms of the service of known winding machines, which are otherwise basically intended for the service of a skilled worker.

A toroid means a geometric body formed by the rotation of an arbitrary geometric figure around an axis - the center, with the axis of rotation - the center lying outside the surface of the selected figure.

In practice, however, this term is used for types of transformers that have a core shape similar to or identical to a toroid. The name toroid is generally accepted in practice for these types of transformers.

Problems of the current state of the art in this field:

The current state of the art of machines for winding thin wires as additional elements on toroids as workpieces or cores representing toroidal transformers does not allow a fully automatic process, since the thin wire behaves unevenly in space, before and after the winding phase, or it takes random positions in space, which the robot cannot detect, and therefore a human is needed to detect the wire in each cycle, grasp it and lead it into the next semi-automatic phase of the known process.

This part, performed by the worker, represents the bottleneck of the work process and therefore prevents shorter working hours and consequently does not allow lowering the own price of these products.

In addition, due to human errors, which are of the order of approx. 350ppm, it does not allow very high true put yields, which means in practice well-made products, which are produced without repairs and waste.

This term is generally used in technical industries, where we statistically monitor production quality facts and at the same time high process capabilities (Cp and Cpk), which are also established terms for statistical tracking of production in terms of its quality or capabilities of work processes in terms of statistical quantities.

Winding the wire on toroidal transformers, which is the state of the art known up to now, is only semi-automatic and requires the precise work of a worker in terms of manipulation or wiring of the wire to the winding ring.

The wire is extremely thin and in the room, when it is unloaded, it behaves as desired, i.e. any environmental influence, however small, moves it in an arbitrary direction, which is different for each cycle, so the technical solution of gripping the wire and arresting the wire on the winding ring was impossible until the presented invention, or technically unsolvable, because the manipulator or robot, even if it is equipped with machine vision and other sensors that would determine the position of the wire on the fly, cannot follow or to determine any wire positions in as short a time as required by the winding cycle.

Therefore, in the phase of gripping and arresting the wire on the winding ring, human work is necessary, since the human works in the sense of a regulation loop and not in the sense of steering, and therefore can adapt on the fly to any position of the wire or it can much more easily follow the different positions of the start of the winding wire in each winding cycle and arrest it on the winding ring much more easily.

They arrest it by pushing it through a thin hole on the ring (diameter approx. 0.3mm) and then tying it with a knot.

Because it requires the insertion of a wire with a diameter of approx. 0.1mm through a hole in a ring with a diameter of approx. 0.3mm with extreme precision, and at the same time puts an extreme strain on the worker's eyes, this workplace in the long term produces work-related disabilities in terms of vision and especially problems with the joints due to the forced position, rapid repetitive movements and monotonous work.

This was also confirmed by market research of providers / manufacturers of toroid winding equipment

Known state of the art of winding machines in this area:

There are quite a few suppliers of toroid winding equipment in Europe and the world (Sources: Internet, ETI Report: CWIEME Berlin 2019).

In addition, different methods are used to wind the toroids.

Each of these methods has certain advantages and disadvantages.

Each method is only suitable for a certain type of winding (depending on the dimensions of the core, wire, number of windings,...).

The main manufacturers of winding equipment are the following companies:

RUFF, CREDOTECH, Gorman, Sl-Pro, Marsilli, Auman, Meteor....

A characteristic of all the systems available on the market is that they allow only semi-automatic winding of toroids (certain operations are performed by the operator and certain by the machine).

None of the well-known manufacturers offers or enables a fully automated system that would not require manual handling.

Problems solved by the proposed invention

The technical invention presented in the following eliminates all the listed shortcomings of the currently known systems by enabling robotic or fully automated service, i.e. work with well-known winding machines intended for winding wire on toroidal cores, suitable especially for thin wires with a diameter of approx. 0.1 mm, which is achieved with methods or shapes and functions of grippers, the shape and dimensions of the grooves on the winding ring and the introduction of all other auxiliary systems such as arresting the wire, shaki Š for cutting the wire Ž, etc. and of course the coordinated operation of all systems.

Search for possible conceptual solutions, assessment of critical operations:

From the analysis of the existing solutions available on the market, it is clear that the automation of the winding process is extremely demanding.

The work of operators on winding machines requires a lot of manual dexterity and precise coordination of hand movement and vision, because it is necessary to attach a very thin wire (0.16 mm) for each individual product to the moving machine part, and after finishing the winding, the remaining wire must be removed from the system and properly attach the wound wires to the core.

Attaching the wire to the ring magazine or in existing winding machines, for wires thinner than 0.3 mm, the winding ring is most often made in this way, that the operator must insert the free part of the wire through a hole with a diameter smaller than Imm, which is made for this purpose on the winding ring, and then the wire with attach to the winding ring with the help of a loop.

After finishing the winding phase, the operator cuts the loop with scissors and removes the remaining wire from the winding ring.

As a result, human work on such winding machines is very demanding, physically demanding and consequently low productivity.

This way of working in Europe is only suitable for smaller batches.

At the same time, the described procedure is very unsuitable for automating the process mainly due to the properties (thinness) of the wire.

One of the options is to use a winding machine as a basis with a winding ring, a magazine and a POG drive with a toothed belt, replacing the operator's work with an industrial robot.

For this purpose, in addition to the rest, a system with a 6-axis robot and a demanding optical system for 3D capture and image analysis would be needed.

The problem with such systems is that they are generally very expensive.

If we use a cheaper optical system, such a system can be quite unreliable or too time-consuming.

This is due to the fact that it is necessary to accurately analyze the image of the position of the wire, which is very thin and randomly curved in space.

Our presented invention solves the above-mentioned shortcomings of semi-automatic systems, which are known in the state of the art in this field, and enables faster winding cycles, since clamping the wire and removing the wire residue is no longer the so-called the time bottleneck of the process.

It is based on the so-called a mechanical system that allows attaching the wire to the hardware part of the winding device with the help of an industrial robot and standard grippers without the use of expensive and complicated optical systems.

In order to enable this solution, we had to prevent random behavior (movement) of the wire or to make such a grip that will always catch the wire in the room.

The requirements that enable mechanical implementation are that the connection of the wire with the machine part must be strong enough so that the wire does not uncontrollably uncoil or break during the winding process, and at the same time it must be possible to reliably and automatically uncoil from the forming joint on the winding ring and to remove the wire after completion. cheering.

Challenges or technical solutions for implementing such a system:

the method of guiding (controlling) the wire, the design and shape of the machine element, which will meet the specified requirements regarding the strength of the joint between the wire and the machine part, to ensure precise guidance and stopping of the winding machine part

The mechanical solution of wire clamping, which is described by our proposed invention and enables the automation of the process, must provide the following:

.) the wire is permanently guided in the hollow part (tube) at the place of manipulation,

.) two grooves of a special shape are additionally made on the ring magazine of the winding machine, which enable a self-locking connection in the tangential direction and an open (non-self-locking) connection in the radial direction to the winding ring,

.) the robot winds the wire on a part of the winding ring between two grooves with a simple circular motion.

The properties of such a joint are:

.) in the event that the force applied by the wire to the ring is directed tangentially to the ring (that is, during the winding phase), the joint is self-closing,

.) in the event that the force with which the wire acts on the ring is directed radially - from the center of the winding ring to the outside (that is, during the phase of removing the remains of the wire after winding), the wire can be reliably removed from the ring,

.) due to the special shape of the grooves on the winding ring described by the proposed invention, the wire does not detach itself from the winding ring during the winding phase due to centrifugal force.

Due to the complexity and lack of knowledge of the solution, we had to confirm the confirmation of the above-described claims by developing and testing a prototype device, otherwise the risk of investing in an automated system would be too great.

During the development phase of the prototype, we made the appropriate shape of the notches on the winding ring, which enable self-supporting of the wire in the tangential direction and an open structural connection in the direction of the force of the wire in the radial direction on the winding ring.

During the construction development phase, a simulation of the movement of the selected 6-axis robot was also made based on a virtual 3D model using the Robotstudio software tool. With this, we got a fairly accurate estimate of the expected machine cycle time (+/- 15%) and checked the reach of the robot to all key positions.

The presented invention is described in the following first with a description of the pictures:

1. Figure 1 shows the complete automated winding machine in the ANS design with the R robot on the upper side.

2. Figure 2 shows a winding ring NO with grooves U for arresting the wire Ž and a hole IL for the laser that determines the starting point.

3. Figure 2A shows detail A from Figure 2, where the shapes and dimensions of the U grooves on the winding ring NO are visible.

4. Figure 2B shows detail A of Figure 2, where the bore IL on the winding ring NO is visible.

5. Figure 3 shows the central part of the winding machine, where the winding ring NO, the drive of the winding ring PO, the toroid T with the arresting and turning system, the pressure rubber PG, the robotic arm RR with two grippers Pl and P2, the introducer UV, the scissors Š, relief pulley RŠ and wire Ž.

6. Figure 4 shows the central part of the winding machine, where the winding ring NO, the drive POG, the winding ring PO, the toroid T with the arresting and twisting system, the pressure rubber PG and the gripper MO are visible.

7. Figure 5 shows the robotic arm RR with gripper 1 Pl in which the UV introducer is arrested.

8. Fig. 6 shows the same as Fig. 5 only, the gripper 1 Pl is open and the lead is UV free. In addition, it shows the plug Pl.1 and the matching channel Pl.2 into which the winding wire Ž fits.

9. Figures 7 A to 7 G show the winding path of the wire Ž between the grooves U, which is carried out by the introducer UV, which is caught in the gripper Pl and guided by the robot arm RR of the robot R.

10. Figures 8 and 8 A show the uncoupling of the wire Ž from the fit between the two grooves U on the winding ring NU, whereby the wire Ž slides through the gripper Pl, which holds the wire Ž with a certain force via the spring of the winder Pl, and the wire Ž slides on the pin P1.2 .

11. Fig. 9 shows the tensioned unfastened wire Ž held by the gripper Pl as in Fig. 8 A with the scissor ŠK2 raised, which will cut the wire Ž.

For the sake of easier understanding and the known state of the art of semi-automatic winding of toroidal transformers, we have described below all the necessary phases by focusing the description of the operation and the description of the hardware only on the automated part, which is the essence of our proposed invention and which describes the shape of the clamp Pl, which enables multiple functions and matching of the wire Ž, the shape of the U grooves in the winding ring NO and other key elements, and of course the synergy of the interaction of all systems in terms of the kinematics of operation, the bending characteristics of the wire, the size and no. Threaded toroid etc.

Robot R with robotic arm RR is controlled via an electronic system or controller, which is known in the state of the art and is not specifically described.

The robotic arm RR has attached two grippers Pl and P2, which sequentially perform tasks or phases of the process, which are described below.

Process stages:

1. Grasping of the core of the toroid T, which represents the workpiece, with the gripper P2, which is arrested on the robot arm RR of the robot R.

2. Positioning the core of the toroid T on the winding site and arresting it only with the pneumatic gripper PT, and the gripper P2 opens and retracts. The winding ring NO is in the open position. We do not specifically describe this because the state of the art is known and it can be implemented via various mechanical, pneumatic, hydraulic mechanisms or the like.

3. Arrest of the wire Ž, which represents an additional element, in the lead-in UV, which is arrested at the starting position with pneumatic pliers PK. The arresting of the wire Ž is carried out mechanically through the compression of the pneumatic pliers KL. The Ž wire looks from the UV lead-in on the lower side at a distance of approx. 5 mm, which is achieved by cutting from the phase of the previous cycle, which is described below.

4. Closing the winding ring NO by releasing the mechanism, which is a known state of the art and is not specifically described.

5. Grasp the introducer UV with pneumatic pliers PK via gripper P1, or through its design association POZ.

6. Positioning the UV introducer in front of the U grooves on the winding ring NO; in this case, the free end of the wire Ž, which looks out of the UV inlet, is placed in the area between the open jaws of the special gripper for holding the MP.

7. Closing the gripper for holding the MP, thereby arresting the free end of the wire Ž.

8. Releasing the pneumatic clamps KL and thereby releasing the wire in the UV guide to allow the wire Ž to move freely in the UV guide. At the same time, the relief pulley RŠ is released in such a way that it goes down, which allows there to be no tensile forces in the wire Ž.

9. Wrapping the lead-in UV around the grooves U in the amount of one turn and thereby achieving the self-supporting of the wire Ž in the tangential direction relative to the winding ring NO, while such a connection is open in the radial direction and can be unlocked with a force of less than approx. 15% tensile strength of wire Ž, both of which are key to the inventiveness of the described invention and which we describe in detail later. The winding of the wire Ž around the grooves U is shown in figures 7 A to 7 G inclusive, and takes place in such a way that the guide UV leads the wire Ž, which is arrested in a special holder for holding MP (arrest is shown in figure 7 A) perpendicularly to the winding ring NO or groove Ul and then through the groove Ul in the NW direction so that the guide UV is partially lowered down so that the wire Ž is caught in the groove U1, which is shown in Figure 7 A then the guide travels

UV counterclockwise in the NW direction along the winding ring NO up, as shown in Figure 7 C. Then the UV guide turns to the left and passes the wire Ž through the groove U2 in the NW direction to the left, as shown in Figure 7 D. Then the UV guide travels along the winding ring down (parallel to it) in the NW direction, which is shown in Figure 7 E. Then the lead UV travels again in the NW direction to the right and leads the wire Ž again through the groove Ul as in the first phase.

In the first phase, the UV lead does not even need to be lowered, as the wire Ž at the exit from it is bent in an arc for a right angle and thus actually positioned lower than the bottom surface of the UV lead, which travels closely above the winding ring NO and thus (or due to the curvature under the lead-in UV in a perpendicular direction, with respect to the bisector of the lead-in U, the wire Ž travels lower than it, namely in the lower part of the channels Ul and U2. This dimension of the curvature of the wire Ž under the lead-in UV is from 0.5 to Imm. GUI depth and GU2 of the grooves Ul and U2 is GUI - GU2 = Imm. The width ŠU1 and ŠU2 of the U grooves is ŠU1 = ŠU2 = l.5mm, while the upper distance RU between the U grooves is RU = 1.9mm, and the lower distance SRU is SRU = 1.65mm. The radii RO of the U grooves are R = 0.5mm, and the bisector angle between the grooves is KOT = 4 degrees. The width ŠKNO of the KNO channel is ŠKNO = minimum l.2mm, but it can be up to approx. 2mm. . the diameter of the IL bore is 0.8mm, and it is placed through the winding ring NO at an arc angle of 145 degrees from the bisector of the first groove Ul and at a radius of POL = 47.5mm. Since the widths of ŠU1 and ŠU2 are 1.5mm and the width of ŠNKO channel KNO at least l.2mm or more up to 2mm, and the diameter of the lower part of the UV lead-in is Imm, the UV lead-in does not need to be lowered and raised in the phase of winding the wire Ž around the grooves U, in order not to hit the winding ring NO, as it travels through the grooves U and through the KNO channel of the winding ring NO. Such a method is much simpler and much better for the process in terms of reproducibility, so it is used where this condition (the diameter of the opening is smaller than the width of the OD and the width of ŠU1, ŠU2) is met.

10. Releasing the special handle for holding the MP, and at the same time turning the winding ring NO counterclockwise in the direction of the SV according to Figure 2 in the prescribed number of turns, which is intended for winding the toroid T.

In this phase, a wire Ž is wound on the winding ring NO with a length equal to the stretched length of the winding, increased by a technological addition, which serves to grip and manipulate the wire Ž during the winding process. The technological addition of the length of the wire Ž is automatically cut off with the scissors Š after the winding is finished and separated via the gripper Pl and transported via suction to the technological waste storage tank. After completing one turn of the winding ring NO, the relief pulley RŠ rises again and tensionally loads the wire Ž, so that it is wound onto the winding ring NO with the prescribed tension force. The preliminary relief was necessary for the safety of the arrest of the wire Ž in it by the notch U. So that the wire Ž would not be unwound from the match. When the wrapping angle of one turn on the winding ring NO is reached, such a connection of wire Ž in the winding groove or channel KNO self-locking. As soon as the wire Ž is wound on at least half of the circumference of the winding ring NO, the relief pulley RŠ can already return to its starting position upwards and tighten the wire Ž. The relieving pulley RŠ can also be suspended via a spring that determines the tensile force in the wire Ž, when the relieving pulley RS is in the upper or in the starting position.

11. Positioning the UV introducer in the initial position (according to Figure 3) and arresting it with PK pneumatic pliers and then or at the same time, the release of the introducer UV from matches the gripper Pl, at the same time the pneumatic pliers KL arrest the wire Ž, and the gripper Pl retracts.

12. Arrest of wire Ž with robot R, or robotic arm RR at a distance of approx. 20 mm below the UV introducer, which is carried out with the Pl gripper through mechanical compression of the PP surfaces of the Pl gripper. At the end of this phase, the wire Ž, approximately 5 mm below the introducer UV, is cut by automatic scissors Š, which can be performed in several possible ways. The cut wire Ž protrudes approx. 5 mm from the UV lead and is ready for the next cycle. At the same time, or before the wire Ž is cut, at the beginning of the winding of the wire Ž on the toroid T, in the lower left part (according to Fig. 2) to the winding ring NO in which channel KNO the wire Ž is wound, to the wire Ž or on the edges radially to the winding ring NO, is pressed by the compression rubber PG to prevent the winding wire Ž from falling out (derailing) from the channel KNO in the winding ring NO.

13. The path of the gripper Pl and the wire Ž cut off with it (the part that is wound on the winding ring NO) to the left position above the winding ring NO and through it to the gripper MO, which arrests the wire Z with a squeeze, and the gripper Pl opens and with it releases wire Ž and immediately after that it releases and withdraws.

14. The path of the gripper MO downwards and thus the tightening of the wire Ž, which is wound on the winding ring NO, and at the same time the winding phase takes place with the rotation of the winding ring NO in the NE direction anticlockwise, according to figure 2. When no. of threads, the winding ring NO is permanently stopped. The winding step is achieved by simultaneous rotation of the arrested core of the toroid T, which is a known state of the art and is not specifically described. After half to one turn of the winding ring NO, the pressure rubber PG is released, as there is no longer any danger of the wire Ž derailing from the winding ring NO or of its KNO channel. The starting state (position) of the winding ring NO is detected via a laser pulse, which shines through the bore IL on the winding ring NO and is in a precisely defined position (in an enveloping angle of 145 degrees from the middle of the groove Ul) and provides information about the reached starting point of the servo drive with drive wheels POK, which drive the toothed belt Z J, which drives the winding ring NO, which is guided from the inside by supporting or bearing - hereinafter referred to as NK inner wheels. The entire drive is called the winding ring drive POG.

15. The path of the gripper Pl to the left above the winding ring NO and through it to the position where it catches the wire Ž via its shape Pl.2 and then leads it into the channel Pl.2.. The gripper Pl travels at right angles to the winding ring NO towards the middle of the ANS construction, it turns to the left by approx. 90 degrees, thereby causing the wire Ž to slip between the surface PP above the plug Pl. 1. Then the gripper Pl closes and compresses the wire Ž through the force of the spring of the gripper Pl.

16. The wire Ž was previously in a random position above the upper left part of the winding ring NO, and the gripper Pl caught the wire Ž with its conical shape and specially made channel Pl.2 and rotations and introduced it into the channel Pl.2. When the wire Ž is caught between the surface PP of the gripper Pl, the gripper Pl is compressed by the spring only with a certain force, and the wire Ž is caught above the plug P 1.1 and can slide past the plug Pl.l through the gripper Pl with a certain preload force and due to plastic deformation ( bending) of the wire Ž after the plug Pl.l achieves an even higher pretension force, which is constant.

17. The winding ring NO is opened as described in point 2.

18. Gripper Pl travels to the left and partially down - relative to the winding ring NO. And when it reaches a position perpendicular to the U grooves, it travels radially from the U grooves and in this way unties or releases the wire Ž from fits in the grooves U on the winding ring NO, since the connection with the shape of the grooves U is made in such a way that it is self-memorizing only in the tangential direction, which is the key to the inventiveness of the described invention. The winding ring NO also has an IL bore through which the laser shines and determines the final or starting point - the position of the winding ring NO.

19. Then the gripper Pl travels upwards to the position below the introducer UV and at the same time through the force of pretension of the wire Ž, which is determined by the spring in the gripper and the pin P. 1.1. gripper P1, continuously stretches the wire Ž with a constant pretensioning force, which is achieved by sliding through the gripper Pl and around its plug Pl.l.

20. Next, the manipulator sticks a label (adhesive tape) on the winding, thereby preventing the winding from unwinding when the wire Ž is no longer pre-tensioned by grippers Pl and MO.

21. The other scissors ŠK2 are brought under the wire Ž and cut off under the gripper Pl, and at the same time the gripper MO is opened and the wire Ž is released from the match.

22. The gripper Pl travels with the wire residue Ž above the suction duct, then it opens and the wire residue Ž flies into the suction duct where it is collected as technological waste.

23. The gripper P2 arrests the toroid T, which the gripper of the toroid previously releases, and the gripper P2 carries it to the storage position via the robotic arm RR. controls.

24. The process repeats steps 1 to 24 inclusive.

Grippers Pl and P2 are mounted at a mutual angle of 90 degrees on the robotic arm RR, which is operated by the robot R, which is mounted on the top of the entire machine in the ANS construction and works upside down due to rigidity and minimal space occupation and consequently accuracy.

This also enables easier and faster access to all the required positions for carrying out the above-described phases of the automatic wire winding process on toroidal transformers.

In addition to movement in space, the arm of the robot RR also has movement around the axis on which grippers Pl and P2 are attached.

Due to this movement, the grippers can be changed faster and thus the so-called process bottlenecks in terms of timing.

The wire Ž for winding is stored in the lower part of the ANS structure of the entire machine and wound on a reel, and it travels via pulleys, which are not specifically described because the state of the art is known, via the relief pulley RŠ, which has the task of relieving the tension force in the wire Ž in phase arresting the wire on the winding reel NO, as described in the previous points. The wire Ž then travels through the lead-in UV, which is arrested or moved in space by the gripper Pl, as previously described in the explanation of the kinematics of the individual work phases.

The inventiveness of the Ž wire installation is also in the introduction of the relief pulley RŠ, which allows the tension forces in the Ž wire to be relieved and thus enables the automatic arrest of the Ž wire via the grooves

U winding ring NO as previously described in the explanation of the individual phases of the work process of automatic winding of toroidal transformers.

The cores of the toroids T are supplied by the supplier and are placed in special pallets according to a certain grid at Imm precisely so that the robot R with the gripper P2 can take them out in the order determined by the control.

Similarly, wound Toroids T (finished products) are stacked into nests of pallets via the robot R, which is controlled by the steering wheel and its robot arms RR, which guides the gripper P2. certain carriers of the finished products, which can be the same as for the toroid cores T and, which later in the course of the work process, according to the established know-how, which is the known state of the art, we also control according to the correct electrical resistance, which is determined according to the specifications of the toroid T and achieved with the correct and undamaged number of wire wraps Ž around the core of the toroid T.

The winding ring NO is guided by the inner wheels NK in a clockwise direction NE.

It is driven via drive wheels PK, which have built-in teeth, which drive the toothed belt ZJ, which embraces the winding ring NO and drives it.

The toothed belt Z J also has the function of closing the wire Ž in the channel of the winding ring NO and thereby determines the winding force of winding the wire Ž on the toroid T, because through its elasticity and pretension it prevents the wire Ž from flowing out too quickly (derailing) during the winding phase on the toroid T.

The winding of the wire Ž on the toroid T is conditioned by the controlled outflow of the wire Ž from the channel KNO of the winding ring NO.

It is also very important that the winding ring NO has an inner radius RO of at least 0.5 mm, which prevents damage to the varnish of the wire Ž, and the roughness of its surface must be level N5 or finer. This radius is the same as all the radii in the grooves Ul and U2 on the winding ring NO and is marked the same by RO.

The RŠ relief pulley is arrested via a pneumatic cylinder, which lowers and raises it as described in previous points 8 and 9.

In the closing phase of the winding ring, NO is necessary, due to the safety of the joint, which prevents tearing or wire damage Ž when winding on the NO winding ring, slight pressure with the finger in the direction of closing the NO winding ring, which is used in known processes that are semi-automatic.

In our presented invention, we used a pneumatic cylinder of smaller dimensions, which acts via a lever on the surface of the NO winding ring and thus ensures the correct position of the free part of the NO ring before closing. After the closing phase of the winding ring, the lever moves away from the surface of the ring and thus enables unimpeded rotation of the ring.

This ensured uninterrupted winding and prevented damage to wire Ž that would occur when passing through the not fully compressed joint of the winding ring NO.

Winding the wire Ž on the winding ring NO or between its U grooves with the goal that the joint is self-closing in the tangential direction and open in the radial direction (that is, the wire Ž can be taken out tangentially from the U grooves without force), is a key condition for complete automation of the process, which is why we describe it in detail below .

This phase is previously described under number 9.

In order to ensure the requirements of the wire wrapping joint Ž, which we have previously stated, we made U grooves of special shapes in the winding ring NO, which is shown in Figures 7 A to 7 G.

For the sake of understanding, we describe in more detail the details of the previously detailed stage 9, which deals with winding the wire Ž between the grooves U.

The robotic arm RR, guided by the robot R in accordance with the program, guides the gripper Pl in which the UV guide is clamped, from which the end of the wire Ž is visible at a distance of 5 mm (in the previous cycle, the wire Ž was cut with scissors Š so that guide the end of the wire Ž to the area approximately 6mm to the right of the edge of the ring (according to Fig. 7 A) so that the end of the wire Ž is placed between the open jaws of the special gripper for holding the MP.

This is followed by the closing of the special gripper for holding the MP and thereby arresting the free end of the Ž wire. Then the relief pulley RŠ moves down and relieves the wire Ž, the pneumatic clamps PK on the UV lead-in open so that the wire Ž can slide freely over the UV lead-in without loads, since the relief pulley has moved down and released the tensile force in the wire Ž.

Then the robotic arm RR, guided by the robot R, guides the guide U around the grooves U and thus the wire Ž, which is arrested in a special holder for holding the MP, turns over the groove Ul and the groove U2 for one turn in the NW direction as previously detailed described in point 9.

When one turn is achieved (subject to the self-supporting force of the joint that we want to achieve), the introducer UV is placed in a position above the middle of the winding ring NO so that the subsequent phase of winding the wire Ž into the channel KNO of the winding ring NO is carried out without the possibility of wire Ž is derailed from the KNO channel and the process continues according to the stages previously described.

Of course, several wraps of wire Ž could also be performed, but due to the reduction of the time of this phase, which means the so-called the bottleneck of the process in terms of the takt time, which of course must be as short as possible, is to perform only one turn that meets the conditions of self-reliance in the radial direction.

The joint of the wound wire Ž made in this way between the grooves U is extremely self-locking in the tangential direction and easily transfers the tensile loads of the wire that occur when winding on the winding ring NO, and at the same time, due to the elasticity of the wire Ž, which wraps around the grooves U after the tension force is finished, , partially relieves and does not create a pressure force on the edges of the U grooves, which would cause a frictional force, so such a joint in the radial direction is open or the coiled wire Ž can be removed from the trap with minimal radially directed force or of the joint between the grooves of the U. This phase is previously described under number 18.

Figures 8 and 8 A show the radial uncoupling of the wire Ž from the fit between the grooves U on the winding ring NO.

This phase occurs in such a way that the winding ring NO exists in a certain place, which is determined by the hole IL through which it shines the laser and which transmits the command to the drive POG of the winding ring NO to stop it.

The robot R positions the robot arm RR in such a way that the gripper Pl, which via the spring and its surfaces PP, compresses the wire Ž, namely by giving the direction of the wire Ž from the gripper Pl to the middle between the two grooves U, radial to the winding ring NO and in the same plane and perpendicular to the U grooves.

The robot R moves the gripper Pl radially from the winding ring NO outwards (perpendicular to the grooves U) and thereby takes the wire Ž out of the fit between the grooves U, and the remaining part of the wire Ž, which is wound on the totoid T, is tensioned with a certain pretensioning force that reaches with the fact that the wire Ž slides through the grip of the gripper Pl, between the surfaces PP and when the wire Ž slides to the plug Pl.l, it also slides over it and causes an increase in the pretensioning force, because the wire Ž has to plastically transform over the plug PP, while slides past it, since the gripper Pl is turned approximately perpendicular to the direction of tensioning of the wire Ž.

This phase is also previously roughly described in points 18 and 19.

When the wire Ž is taken out of the fit between the two grooves U, the gripper Pl starts to rise towards the starting point of the position of the introducer UV and at the same time increases the distance from the winding ring NO, which is fixedly arrested. This achieves a uniform pretension of wire Ž with the previously described system.

When it reaches the upper point, it stops, and the wire Ž reaches a position parallel to the toroid T and is in the same plane as the rest of the wound wire on the toroid T.

If the wire Ž were now disconnected from the gripper Pl, the threads of the wound wire Ž on the toroid T would become loose, so it is necessary to fix the threads of the wire Ž on the toroid T before releasing the wire Ž.

We do this by pasting a self-adhesive tape over them, which connects the turns of wire Ž and fixes them to the toroid T, thus preventing them from becoming loose.

This phase is previously described in point 20.

Then follows a phase in which the other scissors ŠK2 are brought under the wire Ž and cut off under the gripper Pl, while at the same time the gripper MO is opened and the wire Ž is released from the match, which was previously described under point 21.

The gripper Pl deposits the remainder of the wire Ž via the suction channel, which is previously described subpoint 21.

Phases 22 and 23 follow, which are described under items 22 and 23, but do not demonstrate excesses of inventiveness, but are indispensable for the complete automation of the described process.

Claims (14)

Patent claims 1. Automated device and process of winding the wire of toroidal transformers, characterized by the fact that it consists of: from the drive (POG), which via the drive wheels (POK) and the toothed belt (ZJ) in a clockwise direction (SV), drives the winding ring (NO) with grooves (U) and bore (IL), and said winding ring is internally supported with inner wheels (NK), the opening mechanism of said winding ring (NO), - gripper (MO), - an upside-down robot (R) with a robot arm (RR) matching a gripper (Pl) and a gripper (P2), - introduction (UV), which has pneumatic pliers (KL), which compress or arrest the wire (Ž), which represents the additional element, - relief pulley (RŠ), which relieves the tension force in the wire (Z) by moving downwards and vice versa when moving upwards, - pneumatic pliers (PK), which arrest said introducer (UV) when it is not arrested by the gripper (Pl), - pneumatic gripper (PT), which arrests the workpiece toroid (T) when it is not arrested by the gripper (P2), - construction (ANS), which rigidly connects all parts, - presses the elastic band (PG), which moves and moves towards the channel (KNO), - Scissors (Š) and (ŠK2), - a special holding grip (MP). 2. Automated device and process of winding the wire of toroidal transformers, characterized by it, gives the process as follows; -gripper (P2), which is arrested on the robot arm (RR), the robot (R) with its shape grasps the core of the toroid (T), which represents the workpiece, and positions it in the winding position where it is arrested by the pneumatic gripper (PT), the gripper ( P2) opens and retracts, and the winding ring (NO) is in the open position; - then the arresting of the wire (Ž) follows by pressing the pneumatic pliers (KL), which is an integral part of the lead-in (UV), which is arrested in the starting position with the pneumatic pliers (PK), and the wire (Ž) looks from the said lead-in (UV) to the bottom side in a distance of 5 mm, -followed by the closing of the winding ring (NO); - this is followed by grasping the introducer (UV) with pneumatic pliers (PK) via the gripper (Pl) via its form-fitting connection (POZ); - this is followed by the positioning of the introducer (UV) arrested in the gripper (Pl) and parallel pulling of the wire (Ž), with the robotic arm (RR) perpendicularly in front of the grooves (U) on the winding ring (NO) in the area of the special holding gripper (MP), so that the free end of the wire (Ž), which looks out of the inlet (UV), is placed between the open jaws of the special holding gripper (MP), -followed by the closing of the special holding gripper (MP) in which the free end of the wire (Ž) is frictionally arrested, - this is followed by the release of the pneumatic pliers (KL) and thus the release of the wire (Ž) in the lead-in (UV) and parallel movement of the relief pulley (RŠ) downwards, - this is followed by wrapping the guide (UV) around the grooves (U) in the winding ring (NO) in the direction (NW) and thus unwinding the wire (Ž) from the reel where it is wound as a semi-finished product, - this is followed by the release of the special holding grip (MP) and then the rotation of the winding ring (NO) in the direction (SV) and after completing one turn of the mentioned winding ring (NO), the relief pulley (RŠ) rises again and thereby puts a tensile load on the wire (Ž ), then the winding ring (NO) begins to twist in the direction (SV) and thus the wire (Z) unwinds from the reel where it is wound as a semi-finished product, - this is followed by the positioning of the introducer (UV) to the starting position, while at the same time the winding ring (NO) is twisted clockwise in the direction (SW), and the wire (Ž) slides through the introducer (UV) and when the aforementioned winding ring (NO) is rotated in the prescribed number . turns in the direction (SV), it is stopped by the drive (POG) according to the detection of lacei through the bore (IL) in parallel, the wire (Ž) is unwound from the reel where it is wound as a semi-finished product; - followed by arresting the introducer (UV) with pneumatic pliers (PK) and then releasing the introducer (UV) from the match with the gripper (Pl); - then, in the lower left part, to the winding ring (NO) into which the wire (Ž) is wound, the compression rubber (PG) is pressed against the wire (Ž), and at the same time the gripper (Pl), which guided by a robotic arm (RR), via mechanical pressure of surfaces (PP) grasps or arrests the wire (Ž) at a distance of approx. 20 mm below the lead-in (UV), then the automatic scissors (Š) cut the wire (Ž) 5 mm below the lead-in (UV); - follows the path of the gripper (Pl), which is guided by the robotic arm (RR) and the arrested and cut wires (Z) with it, to the position right above the winding ring (NO) and through it to the gripper (MO), which arrests the wire with a squeeze (Ž), and the gripper (Pl) releases it at the same time and withdraws immediately afterwards; - then the gripper (MO) moves down and thereby tightens the wire (Ž), which is wound on the winding ring (NO), then the winding ring (NO) starts to twist in the direction (SV) and when it reaches one revolution, the rubber band is pressed (PG) moves away, and at the same time, by rotating the winding ring (NO) in the direction (SV) anti-clockwise, the winding phase of the toroid (T) takes place, and when no. of threads, the winding ring (NO) is fixedly stopped, and the winding step on the toroid (T) is achieved by simultaneous rotation of the arrested toroid (T) around its axis; - it follows the path of the gripper (Pl) to the left above the winding ring (NO) and through it to the position where, through its conical shape, it captures the end of the wire (Ž), which emerges from the winding ring (NO) and is located above it in a random position, and goes into the channel (P 1.2) of the gripper (Pl), while the gripper (Pl) travels perpendicularly to the winding ring (NO) towards the middle of the structure (ANS) and also twists clockwise by approx. 90 degrees, thereby causing the wire (Ž ) slips between the open surfaces (PP) above the plug (P 1.1), then the mentioned gripper (Pl) closes and compresses the wire (Ž) through the spring force of the gripper (Pl), and the wire (Ž) is caught above the plug (P 1.1) ; - then the gripper (Pl), guided by the robot arm (RR), travels to the left and partially down, and when it reaches a position perpendicular to the grooves (U), it moves radially from the grooves (U) or from the winding ring (NO) and in this way unties or release the wire (Ž) from the fit in the grooves (U) on the winding ring (NO); - then the winding ring (NO) opens; - then the gripper (Pl) travels upwards to the position below the lead-in (UV) and at the same time via the pretension force of the wire (Ž), which is determined by the spring in the gripper and the pin (P.1.1) of the gripper (Pl), it continuously stretches the wire (Ž); - then the manipulator sticks the label on the coil of wire (Ž); - other scissors (ŠK2) are brought under the wire (Ž) and cut under the gripper (Pl), while the gripper (MO) is opened at the same time; - the gripper (Pl) travels with the wire residue (Ž) above the suction channel, then it opens and the wire residue (Ž) flies into the suction channel where it is collected as technological waste; - the gripper (P2) controlled by the robot (R) and its robotic arm (RR) is arrested by the toroid (T), which holds the gripper of the toroid previously released, and the gripper (P2) carries it via the aforementioned robotic arm (RR) to the storage position or . controls into a specific nest on the pallet for finished products. 3. Automated device and process for winding the wire of toroidal transformers, according to claim 1, characterized in that the gripper (Pl) is constructed in such a way that it has a plug (P 1.1) and a form-fitting connection (POZ) built into the surfaces (PP) and on the upper jaw a specially designed shape in the form of a matching channel (P 1.2). 4. Automated device and process for winding the wire of toroidal transformers, according to claim 1, characterized in that the winding ring (NO) has two grooves (U) and a bore (IL) of dimensions and a mutual relationship, namely; the depth (GUI) and (GU2) of the grooves (Ul) and (U2) is Imm, the width (ŠU1) and (ŠU2) of the grooves (U) is l.5mm, the upper distance (RU) between the grooves (U) is l.9mm , and the lower distance (SRU) is l.65mm, the radii (RO) of the grooves (U) are 0.5mm, the bisector angle between the grooves (KOT) is 4 degrees, and the width (ŠKNO) of the channel (KNO) is at least l.2mm , dimension or the diameter of the bore (IL) is 0.8 mm, and it is placed through the winding ring (NO) at an arc angle of 145 degrees from the bisector of the first groove (Ul) and at its radius POL = 47.5 mm. 5. Automated device and process for winding the wire of toroidal transformers, according to claim 2, characterized in that the dimension of the wire curvature (Z) under the lead-in (UV) in the phase of winding between the grooves (U) is from 0.5 to Imm. 6. Automated device and process for winding the wire of toroidal transformers, according to claim 1, characterized in that the diameter of the lower part of the lead-in (UV) does not exceed the dimension Imm. 7. Automated device and process for winding the wire of toroidal transformers, according to claim 2, characterized in that the winding of the wire (Ž) takes place between the grooves (U) in such a way that the conductor (UV) leads the wire (Z), which is previously arrested in special holding gripper (MP), perpendicularly through the groove (Ul) in the direction (NW) so that the conductor (UV) is partially lowered in the first stage, thereby catching the wire Ž in the groove (Ul), then the conductor travels (UV) clockwise in the direction (NW) along the winding ring (NO) upwards, then the guide (UV) turns to the left and leads the wire (Ž) through the groove (U2) in the direction (NW) to the left, then the guide (UV) travels ) next to the winding ring parallel to it down in the (NW) direction, then the guide (UV) travels again in the (NW) direction to the right and leads the wire (Ž) again through the groove (Ul). 8. Automated device and process of winding the wire of toroidal transformers, according to claims 2 and 6, characterized in that when the condition is met, the diameter of the lead-in (UV) is smaller than the width (ŠKNO) and the width (ŠU1) and the width (ŠU2), the lead-in (UV) does not need to be lowered and raised in the phase of winding the wire (Ž) around the grooves (U). 9. Automated device and process for winding the wire of toroidal transformers, according to claim 7, characterized in that the conductor (UV) does not even need to be lowered in the first phase, since the wire (Ž) at the exit from it is bent in an arc at a right angle and thus actually positioned lower than the lower surface of the introducer (UV), which travels closely above the winding ring (NO) and thus or due to the bending of the wire (Ž) under the lead-in (UV) in a perpendicular direction to the bisector of the lead-in (UV), the wire (Ž) travels lower than it, namely in the lower part of the channels (Ul) and (U2), the dimension of the bending of the wire (Ž) under and for introducers (UV) it is from 0.5mm to Imm. 10. Automated device and process for winding the wire of toroidal transformers, according to claim 1, characterized in that the lead-in (UV) has fixed pneumatic clamps (PK) which arrest the wire (Ž) according to the control command. 11. Automated device and process for winding the wire of toroidal transformers, according to claim 2, characterized in that the relief pulley (RŠ) is vertically movable via a pneumatic cylinder, which is controlled via a controller. 12. Automated device and process for winding the wire of toroidal transformers, according to claim 2, characterized in that the winding ring (NO) is guided by the carrier wheels (NK) and driven in the direction (SV) via the drive (POG), which is controlled by email camber, and it consists of drive wheels (POK) with teeth, which drive a toothed belt (ZJ), which presses on the outer part of the winding ring (NO). 13. Automated device and process for winding the wire of toroidal transformers, according to claim 2, characterized in that the gripper (MO) arrests the wire (Ž) via a pneumatic clamp and retracts downwards with a pneumatic drive. 14. Automated device and process for winding the wire of toroidal transformers, according to claim 2, characterized in that all the grippers grip the wire (Ž) through the force of friction, except for the gripper (Pl), which, in addition to this function, also has the function of controlled passage of the wire (Ž) through the gripper (Pl), which is achieved by the fact that the gripper (Pl) presses the surface (PP) onto the wire (Ž) via a spring, and the said wire (Ž) rests and partially twists when the gripper (Pl) is pulled, or wraps around and then slides over the plug (Pl.l) and at the same time between the surfaces (PP).