The automatic winding solution for network transformers is based on customized and flexible equipment, and achieves efficient, stable, and high yield production through a process flow of vibrating disc feeding, automatic winding and cutting, automatic welding, automatic cutting, and finished product discharge. The core advantages are reflected in the precision design and modular changeover capability of the automatic winding and welding stations.
1, Core design features of equipment
Customized development equipment is designed based on the production process characteristics of network transformers 4532, 5365, 6553, 3532 and other series products. Combined with customers' requirements for product processing accuracy and efficiency, it achieves error prevention and error prevention through tooling imitation design and high-precision sensors (such as pressure and position sensors) to avoid quality abnormalities caused by operational errors.
Flexible and modular production operations have strong stability and fast transfer speed. When changing product specifications, only the vibration disc, linear track cover plate, winding clamp, guide pin and other components in contact with the magnetic core need to be adjusted, without the need for overall equipment reconstruction. The replacement time is ≤ 10 minutes, suitable for multi variety and small batch production needs.
2, Process flow analysis
Vibration plate feeding → automatic winding and cutting → automatic welding → automatic cutting → tray discharge of finished products
Vibration disc feeding: The magnetic cores are automatically sorted and transported to the winding station through the vibration disc to ensure feeding continuity and positional accuracy.
Automatic winding and thread cutting: A 3-axis robotic arm (servo motor+screw+guide rail structure) combined with a servo tension wire feeding system achieves single and double line switching, uniform wire feeding (wire breakage rate ≤ 10 times/10H), neat and non overlapping winding, adjustable cutting blade position, and waste wire storage through vacuum suction.
Automatic welding: using pulse heating method, PID algorithm accurately controls temperature (350 ℃ -500 ℃, tolerance ± 5 ℃), welding pressure can be adjusted separately (0.5-3s adjustable), supports separate setting of single/double copper wire pad pressure, equipped with welding head cleaning mechanism (400 mesh sandpaper tape+blowing) and residual paint film cleaning function.
Automatic cutting and finished product discharge: After welding is completed, the finished products are automatically discharged through pallets, achieving unmanned operation throughout the entire process.
3, Equipment core advantage 1 Automatic winding station
Mechanical structure: The 3-axis robotic arm adopts a servo motor+screw+guide rail structure to ensure motion accuracy; The winding mechanism reserves installation positions for switching between single and double wires to meet different product requirements.
Wire feeding system: The servo tension automatic wire feeding system ensures uniform wire feeding and low wire breakage rate (except for material abnormalities); The design of the threading station facilitates quick maintenance and operation.
Synchronous belt mechanism: controlled by a servo motor, ensuring the consistency of machining and assembly of the eight axis fixture base through positioning pins, and improving the stability of winding.
Magnetic core processing: The fixture design prevents material dropping and crushing of the magnetic core, and there is no need for secondary calibration after disassembly, making it easy to change the type; The winding is neatly arranged, and the enameled wire film is intact.
Tangent and waste removal: The winding station integrates a cutting tool function (three-axis servo drive), and the tangent position is adjustable; The waste line mechanism stores waste lines in dedicated boxes through vacuum adsorption or similar methods to avoid contamination.
2. Automatic welding station
Temperature control: Pulse heating method combined with PID algorithm ensures stable heating of the welding head, with a temperature range of 350 ℃ -500 ℃ and a tolerance of ± 5 ℃, to prevent melting of the paint coating.
Pressure regulation: Each solder joint pressure can be set separately, supporting separate adjustment of single/double copper wire pad pressure, equipped with pressure detection device to ensure product coplanarity.
Welding head design: Molybdenum steel welding head (with thermocouple) is used, and the cleaning method is automatic movement of sandpaper belt+blowing air. The sandpaper tray is placed in a box for easy replacement.
Residual cleaning: The equipment has the function of cleaning the residual paint film of the mechanism to avoid affecting the subsequent welding quality.
4, Key equipment parameters
Efficiency: Complete the production of 8 products in 50 seconds, with a utilization rate of ≥ 95% and a yield rate of ≥ 97%.
Accuracy and Range:
Applicable wire diameter: 0.04-0.12mm;
Spindle accuracy: ± 0.02mm;
Winding direction: clockwise/counterclockwise (viewed from the electrode surface);
Winding method: Single and double wires can be switched.
Change ability: Change time ≤ 10 minutes, adaptable to fast switching between multiple varieties.
Environmental requirements:
Voltage: 380V three-phase, frequency 50Hz;
Air pressure: 0.4-0.6Mpa;
Power: 13KW;
Weight: Approximately 2500kg (including cable rack);
Dimensions: 2194 (L) × 1447 (W) × 2195 (H) mm.
Control mode: PLC+HMI, user-friendly interface for parameter adjustment and monitoring.
5, Application Fields and Value
This device is designed specifically for the electronic components industry (network transformers). Through highly customized, flexible, and precise design, it solves the pain points of low efficiency, unstable yield, and long changeover time in traditional winding processes, significantly improving production efficiency and product consistency. It is suitable for large-scale automated production scenarios.
