WO2024040776A1 - 驱动线圈结构、绕线模具及绕制工艺 - Google Patents

驱动线圈结构、绕线模具及绕制工艺 Download PDF

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Publication number
WO2024040776A1
WO2024040776A1 PCT/CN2022/135003 CN2022135003W WO2024040776A1 WO 2024040776 A1 WO2024040776 A1 WO 2024040776A1 CN 2022135003 W CN2022135003 W CN 2022135003W WO 2024040776 A1 WO2024040776 A1 WO 2024040776A1
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WIPO (PCT)
Prior art keywords
lead
coil
tail
arc
initial
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PCT/CN2022/135003
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English (en)
French (fr)
Inventor
叶腾波
朱靖炎
府晓宏
丁炎
沈刚
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苏州东菱振动试验仪器有限公司
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Publication of WO2024040776A1 publication Critical patent/WO2024040776A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H01F5/02—Coils wound on non-magnetic supports, e.g. formers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils

Definitions

  • This application relates to the technical field of vibration test equipment, for example, to a drive coil structure, winding mold and winding process.
  • the drive coil of an induction vibration table is divided into an inner drive coil and an outer drive coil.
  • the inner drive coil can be wound using the original vibration equipment, while the outer drive coil needs to be wound around the coil body. It is made on the inside of the outer coil frame, and the coil body and the outer coil frame are bonded and solidified through adhesive to connect them into one body.
  • This application provides a driving coil structure that can be wound tightly and firmly on the inside of the outer coil frame to ensure that the overall strength of the coil body and the outer coil frame can meet long-term operations.
  • a driving coil structure including:
  • Driving coil the driving coil includes a coil body, the two ends of the coil body are respectively an initial lead and a tail lead, the initial lead and the tail lead are located outside the coil body, and the outside of the coil body Connected with a middle lead;
  • the inner wall of the outer coil frame is provided with an initial lead slot for the initial lead to be embedded, a tail lead slot for the tail lead to be embedded, and a middle lead slot for the middle lead to be embedded, so
  • the outer side of the coil body is connected to the inner wall of the outer coil frame;
  • An outer coil cover is connected to one end of the outer coil frame through screws.
  • This application also provides a driving coil winding mold.
  • the driving coil structure By cooperating with the above-mentioned driving coil structure, it is ensured that the driving coil structure can be accurately and firmly wound on the inside of the outer coil frame, so that the overall strength of the coil body and the outer coil frame can meet the requirements. Long hours of work.
  • a driving coil winding mold including:
  • the driving coil structure is arranged on the outer periphery of the mold body
  • a plurality of reference blocks are detachably arranged on the peripheral side of the mold body at intervals.
  • the end surface of the first arc-shaped plate rests on the reference block.
  • Two adjacent first arc-shaped plates are The filling layer of the board is arranged corresponding to the reference block, and the plurality of lead outlets are arranged in offset positions with the plurality of reference blocks.
  • This application also provides a driving coil winding process. Based on the above-mentioned driving coil structure and the above-mentioned driving coil winding mold, the coil body is tightly and firmly wound on the inside of the outer coil frame to ensure that the coil body is in contact with the outer coil frame. The overall strength can meet the needs of long-term operation.
  • embodiments of the present application provide a driving coil winding process, including:
  • the outer coil frame is configured as a split structure spliced by a plurality of first arc-shaped plates.
  • the initial lead grooves, tail lead grooves and middle lead grooves on the plurality of first arc-shaped plates are respectively connected with the initial leads, tail leads and middle leads.
  • a plurality of first arc-shaped plates are connected to each other and covered on the outer periphery of the driving coil;
  • An adhesive is provided between the coil body and the plurality of first arc-shaped plates, and the winding mold, the coil body and the outer coil former are baked. After the adhesive is cured, the coil body and the outer coil former become one;
  • Figure 1 is a schematic cross-sectional structural diagram of the driving coil structure in the embodiment of the present application.
  • Figure 2 is a schematic structural diagram of a coil body wound by a single wire in an embodiment of the present application
  • Figure 3 is a schematic structural diagram of a bi-wire wound coil body in an embodiment of the present application.
  • Figure 4 is a schematic diagram of the overall structure of the outer coil former in the embodiment of the present application.
  • Figure 5 is a schematic diagram of the overall structure of the driving coil winding mold in the embodiment of the present application.
  • Figure 6 is a schematic cross-sectional view of the driving coil structure and the driving coil winding mold in the embodiment of the present application;
  • Figure 7 is a flow chart of the driving coil winding process in the embodiment of the present application.
  • Mold body 41. Second arc plate; 42. Support plate; 43. Connecting plate; 44. Fixing bolt;
  • connection should be understood in a broad sense.
  • it can be a fixed connection, a detachable connection, or an integral body.
  • It can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be an internal connection between two elements or an interaction between two elements.
  • the meanings of the above terms in this application can be understood according to the circumstances.
  • the term “above” or “below” a first feature on a second feature may include direct contact between the first and second features, or may also include the first and second features. Not in direct contact but through additional characteristic contact between them.
  • the terms “above”, “above” and “above” a first feature on a second feature include the first feature being directly above and diagonally above the second feature, or simply mean that the first feature is higher in level than the second feature.
  • “Below”, “under” and “under” the first feature is the second feature includes the first feature being directly below and diagonally below the second feature, or simply means that the first feature is less horizontally than the second feature.
  • the driving coil structure includes a driving coil 1 , an outer coil former 2 and an outer coil cover 3 .
  • the driving coil 1 includes a coil body 10.
  • the two ends of the coil body 10 are an initial lead 11 and a tail lead 12 respectively.
  • the initial lead 11 and the tail lead 12 are both located outside the coil body 10.
  • a middle lead 13 is also connected to the outside of the coil body 10 .
  • the inner wall of the outer coil frame 2 is correspondingly provided with an initial lead slot 211 for the initial lead 11 to be embedded, a tail lead slot 212 for the tail lead 12 to be embedded, and a middle lead slot 213 for the middle lead 13 to be embedded.
  • the outside of the coil body 10 passes through
  • the adhesive is connected to the inner wall of the outer coil former 2, and the outer coil cover 3 is connected to one end of the outer coil former 2 through screws.
  • the winding starts by considering the tail lead 12 at one end of the coil body 10 as the starting end of the winding. After winding to the middle number of turns of the coil body 10, the middle lead 13 is connected to the wound coil. on the outside of the body 10. Then continue to wind the remaining turns. After the winding is completed, bend the tail lead 12 to the outside of the coil body 10, set the outer coil frame 2 on the outside of the coil body 10, and ensure that the primary lead 11 is embedded in the primary lead slot 211. Inside, the tail lead 12 is embedded in the tail lead slot 212, and the middle lead 13 is embedded in the middle lead slot 213, so that the inner wall of the outer coil frame 2 can be kept close to the coil body 10.
  • the initial lead 11 and the tail lead 12 are the coil body 10
  • the two ends are closely connected through the adhesive filled in the initial lead slot 211 and the tail lead slot 212 after solidification, thereby ensuring that the coil body 10 is more tightly and firmly fixed on the inside of the outer coil frame 2 .
  • the coil body 10 of this embodiment is made of enameled hollow wire, and the coil body 10 is wound by a single wire. In other embodiments, it can also be wound by double wires (as shown in Figure 3), or wound by parallel wires. system, and can also be applied to the coil body 10 wound without leads.
  • one end of the lead 13 is welded to the outside of the coil body 10.
  • the wound coil body 10 is first welded through the middle lead 13 at the welding position, and the welding locations are laminated and wrapped with gauze tape. The firmness of the winding molding of the coil body 10 can be improved.
  • one end of the initial lead 11 , the tail lead 12 and the middle lead 13 away from the coil body 10 all extend in a direction away from the outer coil cover 3 .
  • the initial lead 11 and the tail lead 12 are bent from both ends of the coil body 10 It is formed to ensure the reliability of the winding of the coil body 10 to the greatest extent.
  • the outer coil former 2 of this embodiment has a split structure, which includes at least two first arc-shaped plates 21 connected to each other and to the outside of the coil body 10 .
  • the four first arc-shaped plates 21 form an annular shape after being spliced.
  • the inner walls of the four first arc-shaped plates 21 are sequentially attached to the outside of the coil body 10.
  • a filling layer 22 is provided between each two adjacent first arc-shaped plates 21.
  • the filling layer 22 is composed of epoxy glue, epoxy plates and gauze tape.
  • the number of the first arc-shaped plates 21 can also be three, five, etc., and the number of the first arc-shaped plates 21 can be set according to actual needs.
  • the initial lead slot 211 and the tail lead slot 212 are provided with a bending portion 23 matching the bending place of the initial lead 11 and the tail lead 12 near the first end of the outer coil cover 3.
  • the bending portion 23 is conducive to It effectively fits the transition between the bends of the initial lead 11 and the tail lead 12 .
  • the second ends of the initial lead slot 211, the tail lead slot 212 and the middle lead slot 213 away from the bending portion 23 are respectively provided with lead outlets 24 on the first arc plate 21, and the initial lead 11, the middle lead 13 and the tail lead 12 are far away from each other.
  • the second ends of the coil body 10 respectively extend through the lead outlets 24 .
  • the inner surfaces of the initial lead trough 211, the tail lead trough 212 and the middle lead trough 213 are provided with partitions for insulation.
  • the partitions are made of epoxy boards and epoxy glue.
  • the epoxy glue is applied to the epoxy.
  • the surface of the board is bonded to the inner surfaces of the initial lead groove 211, the tail lead groove 212 and the middle lead groove 213 through the bonding surface coated with epoxy glue.
  • the interlayer can effectively protect the initial lead 11 and the middle lead 13. and the tail lead 12, and better prevent the initial lead 11, the middle lead 13 and the tail lead 12 from being conductive with the outer coil frame 2.
  • the driving coil winding mold includes a mold body 4 and a reference block 51 .
  • the mold body 4 is a split structure, which includes at least two interconnected second arc-shaped plates 41.
  • connecting plates 43 are respectively installed at both ends of the four second arc-shaped plates 41.
  • the second arc-shaped plates 41 are plugged into the connecting plates 43.
  • a fixing bolt 44 is threadedly connected between the two connecting plates 43 to drive the coil structure.
  • the number of the second arc-shaped plates 41 can also be three, five, etc., and the number of the second arc-shaped plates 41 can be set according to actual needs.
  • the first ends of the four second arc-shaped plates 41 are plugged into the connecting plate 43, and then another connecting plate 43 is installed and plugged into the second ends of the four second arc-shaped plates 41.
  • the two connecting plates 43 are locked and fixed using the fixing bolts 44, thereby realizing the erection of the mold body 4.
  • the second arc plate 41 is separated from the connecting plate 43, so that the outer coil former 2 and the coil body 10 can be efficiently separated from the mold body 4. .
  • a plurality of reference blocks 51 are detachably arranged at intervals on the peripheral side of the mold body 4 .
  • the reference block 51 is installed on the outer arc surface of the second arc plate 41 through bolts.
  • This embodiment includes four blocks. The size of each reference block 51 is maintained.
  • four reference blocks 51 are arranged at intervals on the circumferential side of the mold body 4 and are arranged along the circumferential direction of the mold body 4. The end surfaces of the first arc plate 21 rest on the end surfaces of the reference blocks 51, and the two adjacent second arc-shaped plates 21 rest on the end surfaces of the reference blocks 51.
  • the filling layer 22 of an arc-shaped plate 21 is arranged corresponding to the reference block 51 , and the plurality of lead outlets 24 are arranged in a staggered position with the plurality of reference blocks 51 .
  • the arrangement of the reference block 51 can, on the one hand, play a role of bridging support for the four first arc-shaped plates 21 and provide a positioning reference plane for the outer coil former 2 .
  • the support space formed by the reference block 51 to support the outer coil former 2 and the space reserved between adjacent reference blocks 51 can facilitate the operator to handle the initial lead 11 , the middle lead 13 and the tail lead 12 .
  • a lead positioning device 520 is provided on the outer periphery of the mold body 4 .
  • the lead positioning device 520 is configured to respectively fix one end of the initial lead 11 , the tail lead 12 and the middle lead 13 on the mold body 4 .
  • the lead positioning device 520 includes a lead positioning block 52.
  • the lead positioning block 52 is made of metal and has a concave shape as a whole.
  • one end of the three lead positioning blocks 52 is arranged in one-to-one correspondence with the three lead outlets 24 of the initial lead 11, the tail lead 12 and the middle lead 13.
  • the initial lead 11, the tail lead 12 and the middle lead 13 extend from the lead outlet 24.
  • the lead 13 will be inserted into the lead positioning block 52 to achieve fixation.
  • the outer circumference of the mold body 4 is provided with a plurality of reference lines 54 that coincide with the positions of the initial lead 11 , the tail lead 12 and the middle lead 13 , and the reference lines 54 are in contact with the lead positioning blocks 52 at the same time. coincide.
  • the addition of the reference line 54 can accurately locate the winding starting position of the tail lead 12, the welding position of the middle lead 13 and the winding end position of the initial lead 11.
  • the lead outlet 24 is kept corresponding to the reference line 54, so that the initial lead slot 211, the tail lead slot 212 and the middle lead slot 213 on the first arc plate 21 can be aligned with the initial lead 11 , the tail lead 12 and the middle lead 13 correspond one to one, and the positioning accuracy is higher.
  • a bending positioning block 53 is provided on the outer periphery of the mold body 4. After the winding of the coil body 10 is completed, the starting end of the initial lead 11 is bent around the bending positioning block 53 and passes through the coil body. 10 returns to the outside of the coil body 10, and the end of the initial lead 11 is exactly fixed on the lead positioning block 52.
  • the driving coil winding mold of this embodiment also includes a pressing ring 55 and a holding hoop 56 for fixing the coil body 10 and the outer coil former 2 on the four peripheral sides of the mold body.
  • the pressing ring 55 is disposed on the peripheral side of the mold body 4, and a first screw 551 is provided on the mold body 4.
  • a first screw 551 is provided on the mold body 4.
  • the pressing ring 55 is sleeved on the peripheral side of the mold body 4, and the connecting plate 43 in the mold body 4 is threadedly connected with
  • the first screw 551 is provided with an outer coil former step 25 on the outer edge of the inner arc surface of the first arc-shaped plate 21.
  • the end of the first screw 551 can be in contact with the end surface of the pressing ring 55.
  • the connecting plate 43 is also provided with a second screw 552 that is threaded and disposed offset from the first screw 551.
  • the end of the second screw 552 can abut against the end surface of the first arc plate 21.
  • By screwing the second screw 552 can push the first arc plate 21 to keep close contact with the reference block 51 . Therefore, adjusting the first screw 551 and the second screw 552 can ensure that the axial size and axial position of the coil body 10 and the outer coil former 2 remain consistent.
  • the hoop 56 is provided on the peripheral sides of at least two first arc-shaped plates 21 .
  • the hoops 56 are arranged on the peripheral sides of the four first arc-shaped plates 21, which can ensure the outer diameter size and shape requirements of the outer coil frame 2, so that after the subsequent solidification molding and demoulding, the subsequent steps can be reduced.
  • the operation reduces the risk of damage to the outer coil former 2 and the coil body 10 caused by secondary processing, and improves the reliability of curing.
  • this embodiment also provides a driving coil winding process, which includes the following steps based on the above driving coil structure and the above driving coil winding mold:
  • the outer coil former 2 is configured as a split structure composed of a plurality of first arc-shaped plates 21.
  • the initial lead slots 211, the tail lead slots 212 and the middle lead slots 213 on the plurality of first arc-shaped plates 21 are respectively Corresponding to the initial lead 11 , the tail lead 12 and the middle lead 13 , a plurality of first arc-shaped plates 21 are connected to each other and cover the outer periphery of the driving coil 1 .
  • a hoop 56 is provided on the outside of the first arc plate 21 to press the first arc plate 21 and the coil body 10 on the winding mold;

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Motor Or Generator Frames (AREA)
  • Electromagnets (AREA)

Abstract

本申请公开了一种驱动线圈结构、绕制模具及绕制工艺，驱动线圈结构包括驱动线圈、外线圈架和外线圈盖，驱动线圈包括线圈本体，线圈本体的两端分别为初引线和尾引线，初引线和尾引线均位于线圈本体的外侧，线圈本体的外侧连接有中引线，外线圈架内壁上对应地设置有供初引线嵌入的初引线槽、供尾引线嵌入的尾引线槽以及供中引线嵌入的中引线槽，线圈本体的外侧连接于外线圈架的内壁上，外线圈盖通过螺钉连接于外线圈架的一端。

Description

驱动线圈结构、绕线模具及绕制工艺
本公开要求在2022年8月26日提交中国专利局、申请号为202211034824.1的中国专利申请的优先权，以上申请的全部内容通过引用结合在本申请中。
技术领域
本申请涉及振动试验设备技术领域，例如涉及一种驱动线圈结构、绕制模具及绕制工艺。
背景技术
相关技术中，感应式振动台的驱动线圈与常规的振动台相比，其分为内驱动线圈和外驱动线圈，内驱动线圈能够采用原振动设备绕制，而外驱动线圈需要将线圈本体绕制在外线圈架的内侧，通过粘接剂将线圈本体和外线圈架粘接并固化后连接为一体。
随着我国工业和科学技术的发展，感应式振动台越来越普及，对感应式振动台的要求越来越高，大型感应式振动台的推力大，加速度高且工作温度较高，原有的驱动线圈结构的整体强度较低，已无法满足大型感应式振动台的长时间作业。因此，上述问题亟待改善。
发明内容
本申请提供了一种驱动线圈结构，其能够紧密且牢固的绕制在外线圈架的内侧上，确保线圈本体与外线圈架的整体强度能够满足长时间作业。
第一方面，本申请实施例提供了一种驱动线圈结构，包括：
驱动线圈，所述驱动线圈包括线圈本体，所述线圈本体的两端分别为初引线和尾引线，所述初引线和所述尾引线均位于所述线圈本体的外侧，所述线圈本体的外侧连接有中引线；
外线圈架，所述外线圈架的内壁上对应地设置有供所述初引线嵌入的初引线槽、供所述尾引线嵌入的尾引线槽以及供所述中引线嵌入的中引线槽，所述线圈本体的外侧连接于所述外线圈架的内壁上；
外线圈盖，所述外线圈盖通过螺钉连接于所述外线圈架的一端。
本申请还提供了一种驱动线圈绕制模具，通过配合上述驱动线圈结构，确保驱动线圈结构能够精准且牢固的绕制在外线圈架的内侧上，使线圈本体与外线圈架的整体强度能够满足长时间作业。
第二方面，本申请实施例提供了一种驱动线圈绕制模具，包括：
模具本体，所述驱动线圈结构设置在所述模具本体的外周；
基准块，多块所述基准块间隔地可拆卸设置于所述模具本体的周侧，所述第一弧形板的端面搁置于所述基准块上，相邻两个所述第一弧形板的所述填充层与所述基准块相对应设置，多个所述引线出口均与多块所述基准块错位布设。
本申请还提供了一种驱动线圈绕制工艺，通过基于上述驱动线圈结构和上述驱动线圈绕制模具，将线圈本体紧密且牢固的绕制在外线圈架的内侧上，确保线圈本体与外线圈架的整体强度能够满足长时间作业。
第三方面，本申请实施例提供了一种驱动线圈绕制工艺，包括：
将线圈本体的第一端的尾引线固定在引线定位装置上，沿绕制模具绕制线圈本体至其中间匝数；
将中引线的一端固定在引线定位装置上，并焊接中引线于已绕制的线圈本体的外侧；
继续绕制线圈本体，将线圈本体的第二端的初引线牵引至驱动线圈的外侧并与引线定位装置相连接，以形成驱动线圈；
外线圈架设置为由多个第一弧形板拼接成的分体结构，将多个第一弧形板上的初引线槽、尾引线槽和中引线槽分别与初引线、尾引线和中引线相对应，多个第一弧形板相互连接并罩设在驱动线圈外周；
在线圈本体与多个第一弧形板之间设置粘接剂，并对绕制模具、线圈本体和外线圈架进行烘烤，在粘接剂固化后，线圈本体和外线圈架成为一体；
将绕制模具与线圈本体和外线圈架分离。
附图说明
图1是本申请实施例中驱动线圈结构的剖面结构示意图；
图2是本申请实施例中单线绕制的线圈本体的结构示意图；
图3是本申请实施例中双线绕制的线圈本体的结构示意图；
图4是本申请实施例中外线圈架的整体结构示意图；
图5是本申请实施例中驱动线圈绕制模具的整体结构示意图；
图6是本申请实施例中驱动线圈结构和驱动线圈绕制模具的剖面结构示意图；
图7是本申请请实施例中驱动线圈绕制工艺的流程图。
图中：
1、驱动线圈；10、线圈本体；11、初引线；12、尾引线；13、中引线；
2、外线圈架；21、第一弧形板；211、初引线槽；212、尾引线槽；213、中引线槽；22、填充层；23、弯折部；24、引线出口；25、外线圈架台阶；
3、外线圈盖；
4、模具本体；41、第二弧形板；42、撑板；43、连接板；44、固定栓；
50、引线定位装置；51、基准块；52、引线定位块；53、弯线定位块；54、基准线；55、压圈；551、第一螺钉；552、第二螺钉；56、抱箍。
具体实施方式
下面结合附图和实施例对本申请作说明。可以理解的是，此处所描述的实施例仅仅用于解释本申请。另外还需要说明的是，为了便于描述，附图中仅示出了与本申请相关的部分而非全部结构。
在本申请的描述中，除非另有明确的规定和限定，术语“相连”、“连接”、“固定”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或成一体；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通或两个元件的相互作用关系。对于本领域的普通技术人员而言，可以根据情况理解上述术语在本申请中的含义。
在本申请中，除非另有明确的规定和限定，第一特征在第二特征之“上”或之“下”可以包括第一和第二特征直接接触，也可以包括第一和第二特征不是直接接触而是通过它们之间的另外的特征接触。而且，第一特征在第二特征“之上”、“上方”和“上面”包括第一特征在第二特征正上方和斜上方，或仅仅表示第一特征水平高度高于第二特征。第一特征在第二特征“之下”、“下方”和“下面”包括第一特征在第二特征正下方和斜下方，或仅仅表示第一特征水平高度小于第二特征。
在本实施例的描述中，术语“上”、“下”、“右”等方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述和简化操作，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作。此 外，术语“第一”、“第二”仅仅用于在描述上加以区分，并没有特殊的含义。
结合图1至图4所示，本实施例提供了一种驱动线圈结构，驱动线圈结构包括驱动线圈1、外线圈架2和外线圈盖3。驱动线圈1包括线圈本体10，线圈本体10的两端分别为初引线11和尾引线12，初引线11和尾引线12均位于线圈本体10的外侧。线圈本体10的外侧还连接有中引线13。外线圈架2的内壁上对应地设置有供初引线11嵌入的初引线槽211、供尾引线12嵌入的尾引线槽212以及供中引线13嵌入的中引线槽213，线圈本体10的外侧通过粘接剂连接于外线圈架2的内壁上，外线圈盖3通过螺钉连接于外线圈架2的一端上。
可以理解的是，通过将线圈本体10一端的尾引线12视为绕制起始端开始绕制，当绕制至线圈本体10的中间匝数后，将中引线13连接在已绕制好的线圈本体10的外侧上。随后再继续绕制剩余匝数，绕制完成后将尾引线12弯折至线圈本体10的外侧，将外线圈架2设置在线圈本体10的外侧上，同时确保初引线11嵌入初引线槽211内，尾引线12嵌入尾引线槽212内，中引线13嵌入中引线槽213内，从而使外线圈架2的内壁能够与线圈本体10保持紧贴，初引线11和尾引线12即线圈本体10的两端通过在初引线槽211和尾引线槽212内填充的粘接剂固化后紧密相连，以此确保线圈本体10更加紧密且牢固的固定在外线圈架2的内侧上。
如图2所示，本实施例的线圈本体10采用漆包空心线，线圈本体10为单线绕制，在其他实施例中还可采用双线绕制(如图3所示)、并线绕制，同时也可适用于无引线绕制的线圈本体10。
本实施例中引线13的一端焊接在线圈本体10的外侧上，利用中引线13将绕制的线圈本体10通过中引线13率先在焊接位置进行焊接，且焊接处均采用纱带进行层叠包裹，能够提高线圈本体10绕制成型的牢固性。
示例性地，初引线11、尾引线12和中引线13远离线圈本体10的一端均朝向于远离外线圈盖3的方向延伸，初引线11和尾引线12由线圈本体10的两端通过折弯而形成，以此最大限度地保证线圈本体10绕制的可靠性。
如图4所示，本实施例的外线圈架2为分体结构，其包括至少两个相互连接并连接于线圈本体10外侧的第一弧形板21。本实施例的第一弧形板21设置有四个，四个第一弧形板21拼接后呈环形，四个第一弧形板21的内壁依次地贴附在线圈本体10的外侧上，每相邻的两个第一弧形板21之间设置有填充层22，填充层22由环氧胶、环氧板和纱带组成。当然，第一弧形板21的数量还可为三个、五个等，第一弧形板21的数量可以根据实际需求设置。
示例性地，初引线槽211和尾引线槽212靠近外线圈盖3的第一端设置有与初引线11和尾引线12的弯折处相匹配的弯折部23，弯折部23有利于与初引线11和尾引线12的弯折处有效地贴合过渡。初引线槽211、尾引线槽212和中引线槽213远离弯折部23的第二端分别在第一弧形板21上设置有引线出口24，初引线11、中引线13和尾引线12远离线圈本体10的第二端分别通过引线出口24伸出。
在一实施例中，初引线槽211、尾引线槽212和中引线槽213的内侧面均设置 有用于绝缘的隔层，隔层为环氧板与环氧胶，环氧胶涂抹于环氧板的表面并通过涂覆有环氧胶的粘接面粘接在初引线槽211、尾引线槽212和中引线槽213的内侧面上，隔层能够有效地保护初引线11、中引线13和尾引线12，并更好地防止初引线11、中引线13和尾引线12与外线圈架2导通。
结合图1至图6所示，本实施例还提供了一种驱动线圈绕制模具，驱动线圈绕制模具包括模具本体4和基准块51。模具本体4为分体结构，其包括至少两个相互连接的第二弧形板41，本实施例的第二弧形板41设置有四个，四个第二弧形板41拼接后呈环形，四个第二弧形板41的两端分别安装有连接板43，第二弧形板41插接于连接板43上，两块连接板43之间螺纹连接有固定栓44，驱动线圈结构设置在模具本体4的外周，即四个第二弧形板41的外弧面上。当然，第二弧形板41的数量还可为三个、五个等，第二弧形板41的数量可以根据实际需求设置。
可以理解的是，将四个第二弧形板41的第一端插接于连接板43上，随后安装另外一块连接板43插接在四个第二弧形板41的第二端上，利用固定栓44将两块连接板43锁紧固定，从而实现模具本体4的搭设。在完成外线圈架2和线圈本体10的粘接剂固化后，将第二弧形板41与连接板43分离，便能高效地将外线圈架2和线圈本体10从模具本体4上分离下来。
示例性地，多块基准块51间隔地可拆卸设置于模具本体4的周侧。如图5所示，基准块51通过螺栓安装至第二弧形板41的外弧面上，基准块51设置有多块，本实施例设置有四块，每块基准块51的尺寸大小保持一致，四块基准块51间隔地设置于模具本体4的周侧且沿模具本体4的周向布设，第一弧形板21的端面均搁置于基准块51的端面上，相邻两个第一弧形板21的填充层22与基准块51相对应设置，多个引线出口24均与多块基准块51错位布设。基准块51的设置，一方面能够对四块第一弧形板21起到两两桥接支撑的作用，为外线圈架2提供定位基准平面。另一方面通过基准块51形成的支撑外线圈架2的支撑空间，以及相邻基准块51之间预留的空间，能够便于操作人员对初引线11、中引线13和尾引线12进行处理。
示例性地，如图5所示，模具本体4的外周设置有引线定位装置520，引线定位装置520设置为分别固定初引线11、尾引线12和中引线13的一端于模具本体4上。引线定位装置520包括引线定位块52，引线定位块52由金属材质制得且整体呈凹型，引线定位块52设置有三块，三块引线定位块52固定在第二弧形板41的外弧面上，三块引线定位块52的一端分别与初引线11、尾引线12和中引线13的三个引线出口24一一对应设置，自引线出口24伸出的初引线11、尾引线12和中引线13将插接在引线定位块52内，以此实现固定。
在一实施例中，模具本体4的外周沿其轴线方向设置有多根与初引线11、尾引线12和中引线13的位置相重合的基准线54，基准线54同时与引线定位块52相重合。基准线54的增设能够精准定位尾引线12的绕线起始位置，中引线13的焊 接位置以及初引线11的绕线末端位置。并在安装第一弧形板21时，通过引线出口24与基准线54保持对应，以便第一弧形板21上的初引线槽211、尾引线槽212和中引线槽213能够与初引线11、尾引线12和中引线13一一对应，定位精准度更高。
在一实施例中，模具本体4的外周设置有弯线定位块53，当线圈本体10绕制完成后，初引线11的起始端绕过弯线定位块53折弯成型，并穿过线圈本体10的上方返回至线圈本体10的外侧，初引线11的末端恰好固定在引线定位块52上。
如图6所示，本实施例的驱动线圈绕制模具还包括用于固定线圈本体10和外线圈架2于模具本体4周侧的压圈55和抱箍56。
压圈55设置于模具本体4的周侧，模具本体4上设置有第一螺钉551，例如压圈55套设于模具本体4的周侧上，模具本体4中的连接板43上螺纹连接有第一螺钉551，第一弧形板21内弧面的外沿设置有外线圈架台阶25，第一螺钉551的端部能够抵接于压圈55的端面上，通过旋拧第一螺钉551能够推动线圈本体10与外线圈架台阶25保持紧贴。连接板43上还设置有如螺纹连接有与第一螺钉551错位布设的第二螺钉552，第二螺钉552的端部能够抵接于第一弧形板21的端面上，通过旋拧第二螺钉552能够推动第一弧形板21与基准块51保持紧贴。从而调节第一螺钉551和第二螺钉552，能够保证线圈本体10和外线圈架2的轴向尺寸和轴向位置保持一致。
抱箍56箍设于至少两个第一弧形板21的周侧。本实施例中，抱箍56箍设于四块第一弧形板21的周侧上，能够保证外线圈架2的外径尺寸和形位要求，以便后续固化成型脱模后，能够减少后续作业，降低了二次加工对外线圈架2和线圈本体10的损坏风险，提高了固化的可靠性。
如图7所示，本实施例还提供了一种驱动线圈绕制工艺，基于上述驱动线圈结构和上述驱动线圈绕制模具，包括以下步骤：
1)将线圈本体10的第一端的尾引线12固定在引线定位装置520中的引线定位块52上，沿绕制模具绕制线圈本体10至其中间匝数；
2)将中引线13的一端固定在引线定位装置520中的引线定位块52上，并焊接中引线13于已绕制的线圈本体10的外侧；
3)继续绕制线圈本体10，将线圈本体10的第二端的初引线11沿弯线定位块53牵引至驱动线圈1的外侧并与引线定位装置520中的引线定位块52相连接，以形成驱动线圈1。在上述绕制过程中还会辅以玻璃丝带、纱带、环氧板等辅件进行绝缘处理；
4)外线圈架2设置为由多个第一弧形板21拼接成的分体结构，将多个第一弧形板21上的初引线槽211、尾引线槽212和中引线槽213分别与初引线11、尾引线12和中引线13相对应，多个第一弧形板21相互连接并罩设在驱动线圈1外周。同时，在第一弧形板21的外侧设置抱箍56，将第一弧形板21与线圈本体10压紧 于绕制模具上；
5)在线圈本体10与多个第一弧形板21之间设置粘接剂，并对绕制模具、线圈本体10和外线圈架2进行烘烤，在粘接剂固化后，线圈本体10和外线圈架2成为一体；
6)将绕制模具与线圈本体10和外线圈架2分离，进行脱模。

Claims (10)

  1. 一种驱动线圈结构，包括：
    驱动线圈(1)，所述驱动线圈(1)包括线圈本体(10)，所述线圈本体(10)的两端分别为初引线(11)和尾引线(12)，所述初引线(11)和所述尾引线(12)均位于所述线圈本体(10)的外侧，所述线圈本体(10)的外侧连接有中引线(13)；
    外线圈架(2)，所述外线圈架(2)的内壁上对应地设置有供所述初引线(11)嵌入的初引线槽(211)、供所述尾引线(12)嵌入的尾引线槽(212)以及供所述中引线(13)嵌入的中引线槽(213)，所述线圈本体(10)的外侧连接于所述外线圈架(2)的内壁上；
    外线圈盖(3)，所述外线圈盖(3)通过螺钉连接于所述外线圈架(2)的一端。
  2. 根据权利要求1所述的驱动线圈结构，其中，所述外线圈架(2)包括至少两个相互连接并连接于所述线圈本体(10)外侧的第一弧形板(21)，相邻两个所述第一弧形板(21)之间设置有填充层(22)。
  3. 根据权利要求2所述的驱动线圈结构，其中，所述初引线(11)、所述尾引线(12)和所述中引线(13)远离所述线圈本体(10)的一端均朝向于远离所述外线圈盖(3)的方向延伸。
  4. 根据权利要求3所述的驱动线圈结构，其中，所述初引线(11)和所述尾引线(12)由所述线圈本体(10)的两端弯折形成，所述初引线槽(211)和所述尾引线槽(212)靠近所述外线圈盖(3)的第一端设置有与所述初引线(11)和所述尾引线(12)的弯折处相匹配的弯折部(23)，所述初引线槽(211)、 所述尾引线槽(212)和所述中引线槽(213)远离所述弯折部(23)的第二端分别在所述第一弧形板(21)上设置有引线出口(24)。
  5. 根据权利要求4所述的驱动线圈结构，其中，所述初引线槽(211)、所述尾引线槽(212)和所述中引线槽(213)的内侧面均设置有用于绝缘的隔层。
  6. 一种驱动线圈绕制模具，基于权利要求4或5所述的驱动线圈结构，包括：
    模具本体(4)，所述驱动线圈结构设置在所述模具本体(4)的外周；
    基准块(51)，多块所述基准块(51)间隔地可拆卸设置于所述模具本体(4)的周侧，所述第一弧形板(21)的端面搁置于所述基准块(51)上，相邻两个所述第一弧形板(21)的所述填充层(22)与所述基准块(51)相对应设置，多个所述引线出口(24)均与多块所述基准块(51)错位布设。
  7. 根据权利要求6所述的驱动线圈绕制模具，其中，所述模具本体(4)的外周设置有引线定位装置(520)，所述引线定位装置(520)设置为分别固定所述初引线(11)、所述尾引线(12)和所述中引线(13)的一端于所述模具本体(4)上。
  8. 根据权利要求7所述的驱动线圈绕制模具，其中，所述模具本体(4)的外周沿其轴线方向设置有多根与所述初引线(11)、所述尾引线(12)和所述中引线(13)的位置相重合的基准线(54)。
  9. 根据权利要求8所述的驱动线圈绕制模具，所述驱动线圈绕制模具还包括：
    压圈(55)，所述压圈(55)设置于所述模具本体(4)的周侧，所述模具 本体(4)上设置有第一螺钉(551)，所述第一弧形板(21)内弧面的外沿设置有外线圈架台阶(25)，所述第一螺钉(551)的端部能够抵接于所述压圈(55)的端面上，以推动所述压圈(55)使线圈本体(10)与所述外线圈架台阶(25)保持紧贴；
    抱箍(56)，所述抱箍(56)箍设于至少两个所述第一弧形板(21)的周侧，所述模具本体(4)上设置有与所述第一螺钉(551)错位布设的第二螺钉(552)，所述第二螺钉(552)的端部能够抵接于所述第一弧形板(21)的端面上，以推动所述第一弧形板(21)使所述第一弧形板(21)与所述基准块(51)保持紧贴。
  10. 一种驱动线圈绕制工艺，基于权利要求1至5中任一项所述的驱动线圈结构，和，权利要求6至9中任一项所述的驱动线圈绕制模具，包括：
    将线圈本体(10)的第一端的尾引线(12)固定在引线定位装置(520)上，沿绕制模具绕制线圈本体(10)至其中间匝数；
    将中引线(13)的一端固定在引线定位装置(520)上，并焊接中引线(13)于已绕制的线圈本体(10)的外侧；
    继续绕制线圈本体(10)，将线圈本体(10)的第二端的初引线(11)牵引至驱动线圈(1)的外侧并与引线定位装置(520)相连接，以形成所述驱动线圈(1)；
    外线圈架(2)设置为由多个第一弧形板(21)拼接成的分体结构，将多个第一弧形板(21)上的初引线槽(211)、尾引线槽(212)和中引线槽(213)分别与初引线(11)、尾引线(12)和中引线(13)相对应，多个第一弧形板(21)相互连接并罩设在所述驱动线圈(1)外周；
    在线圈本体(10)与多个第一弧形板(21)之间设置粘接剂，并对绕制模具、线圈本体(10)和外线圈架(2)进行烘烤，在粘接剂固化后，线圈本体(10)和外线圈架(2)成为一体；
    将绕制模具与线圈本体(10)和外线圈架(2)分离。
PCT/CN2022/135003 2022-08-26 2022-11-29 驱动线圈结构、绕线模具及绕制工艺 WO2024040776A1 (zh)

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