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id="bodycontent"> <div style="width:950px;height:30px;" class="news_content_title"> <h3 style="color:#333;margin:0pt 0pt 0pt 0pt;"> <strong>微型變壓器線(xiàn)圈自動(dòng)繞線(xiàn)機裝置設計及優(yōu)化</strong> </h3><hr width="95%" size="1" noshade> </div> <div style="width:950px; text-align:left; line-height:180%;" class="news_content_body"> 隨著(zhù)電子技術(shù)和信息技術(shù)的高速發(fā)展，微型變壓器在計算機、通訊、航天航空等領(lǐng)域的發(fā)展發(fā)揮著(zhù)越來(lái)越重要的作用。對微型變壓器生產(chǎn)制造的需求量變大，制造要求變高。如何批量生產(chǎn)出質(zhì)量合格的微型變壓器已成為企業(yè)亟需解決的重要課題。目前微型變壓器主要采用標準化、規�；a(chǎn)模式，已到達了半自動(dòng)化生產(chǎn)水平。<br /> 繞線(xiàn)為微型變壓器生產(chǎn)的關(guān)鍵工序，不僅影響產(chǎn)品的外觀(guān)特征，還影響著(zhù)產(chǎn)品的阻抗、漏感、電容等多項品質(zhì)參數�，F今的變壓器繞線(xiàn)技術(shù)研究主要針對較大型的變壓器產(chǎn)品，對微型變壓器的繞線(xiàn)機構研究較少，故設計一種快速優(yōu)質(zhì)的微型變壓器自動(dòng)繞線(xiàn)裝置對于微型變壓器生產(chǎn)具有重大意義。<br /> <p> 微型變壓器產(chǎn)品外觀(guān)尺寸要求如圖1所示。此產(chǎn)品為用于智能手機充電器的微型變壓器，通過(guò)電磁感應原理在兩個(gè)電路之間傳遞電能，基本結構是由磁芯、繞組和底座構成，繞組是采用漆包線(xiàn)繞制而成。 </p> <p> <img src="/upload/image/20200810/20200810120318241824.png" alt="" /> </p> 微型變壓器的自動(dòng)繞線(xiàn)工藝流程的設計難點(diǎn)在于以下兩點(diǎn)：第一，變壓器產(chǎn)品外觀(guān)結構特殊，單個(gè)產(chǎn)品尺寸小、重心不穩；第二，在控制產(chǎn)品生產(chǎn)成本和質(zhì)量的前提下，實(shí)現磁圈繞組銅線(xiàn)自動(dòng)化理線(xiàn)的難度相對較大。<br /> 1 微型變壓器線(xiàn)圈自動(dòng)繞線(xiàn)裝置原理<br /> 1.1 微型變壓器繞線(xiàn)流程<br /> 微型變壓器的原繞線(xiàn)流程為利用人工手持漆包線(xiàn)纏繞于磁圈中，當纏繞圈數達到生產(chǎn)要求時(shí)，將多余線(xiàn)圈剪斷，完成一次繞線(xiàn)流程。<br /> 人工繞線(xiàn)不僅降低了微型變壓器產(chǎn)線(xiàn)整體的生產(chǎn)效率，而且其生產(chǎn)常伴隨著(zhù)線(xiàn)圈圈數錯誤、剪線(xiàn)殘留過(guò)長(cháng)和繞線(xiàn)松動(dòng)等質(zhì)量問(wèn)題。故設計微型變壓器自動(dòng)繞線(xiàn)裝置，提高微型變壓器的生產(chǎn)效率和質(zhì)量。<br /> 1.2 微型變壓器產(chǎn)線(xiàn)構成<br /> 微型變壓器生產(chǎn)線(xiàn)上主要包含7種自動(dòng)加工設備，這些自動(dòng)加工設備分別為：<strong>自動(dòng)繞線(xiàn)機</strong>、點(diǎn)膠機、上底座裝置、烘烤爐、激光去皮裝置、自動(dòng)焊錫機、耐壓測試機和綜合測試機等。應用自動(dòng)加工設備產(chǎn)線(xiàn)每小時(shí)產(chǎn)能與人工產(chǎn)能對比提升了大約5倍。<br /> 自動(dòng)繞線(xiàn)機機械系統機械部分組成主要有：供線(xiàn)機構、繞線(xiàn)機構、剪線(xiàn)機構、排線(xiàn)機構、進(jìn)料機構、機架等。<br /> 人工繞線(xiàn)平均產(chǎn)能為20 pcs/h，因而必須采用<a href="http://m.e-seiyaku.com/" target="_blank"><strong>自動(dòng)繞線(xiàn)機</strong></a>方可滿(mǎn)足生產(chǎn)線(xiàn)產(chǎn)能要求。變壓器生產(chǎn)線(xiàn)中繞線(xiàn)工站預計設置11臺自動(dòng)繞線(xiàn)裝置，不考慮不良品的情況下要求每臺自動(dòng)繞線(xiàn)機至少110 pcs/h的產(chǎn)能，現有繞線(xiàn)機平均產(chǎn)出為95 pcs/h，這對于實(shí)現整條生產(chǎn)線(xiàn)的規定產(chǎn)能造成很大隱患，因而提出對自動(dòng)繞線(xiàn)機關(guān)鍵部位進(jìn)行問(wèn)題分析與改進(jìn)設計。<br /> 1.2 自動(dòng)繞線(xiàn)機機構組成<br /> <p> 現有繞線(xiàn)機機械系統如圖2所示，組成主要有：供線(xiàn)機構、繞線(xiàn)機構、剪線(xiàn)機構、排線(xiàn)機構、進(jìn)料機構、機架等，由同一個(gè)控制系統控制機電部分完成磁圈自動(dòng)繞線(xiàn)這一工序。 </p> <p> <img src="/upload/image/20200810/20200810120377137713.png" alt="自動(dòng)繞線(xiàn)機" width="466" height="203" title="自動(dòng)繞線(xiàn)機" align="" /> </p> <p> 供線(xiàn)機構如圖3所示，主要包含：供線(xiàn)軌道、壓線(xiàn)閥、導線(xiàn)輪組、導輪支架、電機、導線(xiàn)管等6個(gè)部分。 </p> <p> <img src="/upload/image/20200810/20200810120311331133.png" alt="自動(dòng)繞線(xiàn)機" width="465" height="191" title="自動(dòng)繞線(xiàn)機" align="" /> </p> <p> 供磁圈機構如圖4所示，主要包括磁圈限位輪、推料桿、進(jìn)料通道、吹氣管、振動(dòng)盤(pán)5個(gè)部分。 </p> <p> <img src="/upload/image/20200810/20200810120318711871.png" alt="自動(dòng)繞線(xiàn)機" width="471" height="438" title="自動(dòng)繞線(xiàn)機" align="" /> </p> 繞線(xiàn)機構如圖5所示，主要由機架、傳動(dòng)帶、1對排廢輪、限位（銅線(xiàn)）螺釘、光電傳感器、1組刀具、1對圓臺輪組、磁圈頂針、轉角齒輪組等組成。<br /> 1.3 自動(dòng)繞線(xiàn)機的工作流程<br /> 1.3.1儲線(xiàn)過(guò)程<br /> <p> 銅線(xiàn)完成儲線(xiàn)預備繞線(xiàn)階段的動(dòng)力來(lái)源有兩處，一是位于供線(xiàn)機構部分的一對圓柱形導線(xiàn)輪組，儲線(xiàn)開(kāi)始時(shí)由導線(xiàn)輪組提供起始動(dòng)力，后續儲線(xiàn)過(guò)程中供線(xiàn)機構部分的導線(xiàn)輪組持續轉動(dòng)為儲線(xiàn)過(guò)程提供動(dòng)力；二是繞線(xiàn)機構部分的兩對鼓輪，在銅線(xiàn)到達鼓輪處時(shí)鼓輪對其的摩擦力提供一部分的動(dòng)力。這兩種動(dòng)力輪組安裝在同一轉軸上，通過(guò)同步帶與電機輸出端連接，從而保證銅線(xiàn)的速度一致，實(shí)現繞線(xiàn)。動(dòng)力輪組中心軸轉動(dòng)方向如圖6所示。 </p> <p> <img src="/upload/image/20200810/20200810120368276827.png" alt="自動(dòng)繞線(xiàn)機" style="white-space:normal;" width="480" height="264" title="自動(dòng)繞線(xiàn)機" align="" /> </p> 儲線(xiàn)開(kāi)始前，銅線(xiàn)由工人放置在供線(xiàn)軌道上。儲線(xiàn)階段開(kāi)始，壓線(xiàn)閥呈打開(kāi)狀態(tài)。導線(xiàn)輪隨電機輸出主軸轉動(dòng)，同時(shí)帶動(dòng)壓在滾輪下方的銅線(xiàn)往前運動(dòng)通過(guò)輸線(xiàn)管進(jìn)入繞線(xiàn)區域，繞線(xiàn)區域的光電傳感器檢測到銅線(xiàn)儲備圈數達到預設值時(shí)，壓線(xiàn)閥壓緊，銅線(xiàn)不再進(jìn)行輸入動(dòng)作，儲線(xiàn)預備繞線(xiàn)階段完成。<br /> 儲線(xiàn)預備過(guò)程中銅線(xiàn)軌跡為：漆包線(xiàn)從輸線(xiàn)端通過(guò)導線(xiàn)管進(jìn)入繞線(xiàn)區域，接著(zhù)銅線(xiàn)走跡為沿著(zhù)外圈軌跡先穿過(guò)第一組鼓輪中間空隙，隨后穿過(guò)定位好的磁圈繼續往前走，又通過(guò)第二組鼓輪中間空隙，最后回到第一圈圓形軌跡起始點(diǎn)，接著(zhù)往半徑較大的外圈走，再進(jìn)行第二圈、第三圈的儲備，最終儲備好所設定的圈數預備繞線(xiàn)。<br /> 1.3.2磁圈繞線(xiàn)過(guò)程<br /> <p> 儲線(xiàn)完成后，壓線(xiàn)閥下壓壓緊銅線(xiàn)一端，供線(xiàn)機構部分的導線(xiàn)輪組停止轉動(dòng)。繞線(xiàn)過(guò)程如圖7所示，繞線(xiàn)機構的兩對鼓輪分別為輪組Ⅰ和輪組Ⅱ，輪組Ⅰ為繞線(xiàn)機靠前位置的鼓輪組，輪組Ⅱ為與輪組Ⅰ相對位置的輪組。繞線(xiàn)過(guò)程中，輪組Ⅰ、Ⅱ上方的鼓輪中心軸沿順時(shí)針轉動(dòng)，下方鼓輪沿逆時(shí)針轉動(dòng)，鼓輪表面線(xiàn)速度v 1 大于銅線(xiàn)速度v 2 ，因而鼓輪對銅線(xiàn)產(chǎn)生二者相對速度相同方向的摩擦力，以此方式將鼓輪組中間夾著(zhù)的銅線(xiàn)不斷往前拉，儲線(xiàn)內圈銅線(xiàn)接著(zhù)套緊在磁圈上實(shí)現繞組繞線(xiàn)。在光電傳感器感應到繞線(xiàn)圈數達到設定的62圈的時(shí)候，信號發(fā)至控制系統觸發(fā)刀具將銅線(xiàn)剪斷，繞線(xiàn)過(guò)程即完成。 </p> <p> <img src="/upload/image/20200810/20200810120349294929.png" alt="" style="white-space:normal;" /> </p> <p> <br /> </p> 1.3.3卸料過(guò)程<br /> 磁圈兩邊繞組繞線(xiàn)完成后，進(jìn)磁圈機構處的兩組齒輪組將繞好線(xiàn)的磁圈往繞線(xiàn)區域中心位置送，同時(shí)控制系統觸發(fā)推料桿上方的氣閥吹氣，將磁圈網(wǎng)繞線(xiàn)區域中心位置吹出，繞線(xiàn)區中心正對著(zhù)下料口，磁圈到達下料口往下掉進(jìn)半成品儲料倉中。整個(gè)繞線(xiàn)過(guò)程隨即完成。<br /> 2 自動(dòng)繞線(xiàn)裝置的故障分析<br /> 半成品故障類(lèi)型主要分為兩種：一是兩個(gè)磁圈間的銅線(xiàn)沒(méi)有切斷導致半成品不合格，繞組磁圈無(wú)法使用；二是在繞線(xiàn)時(shí)發(fā)生纏線(xiàn)導致繞組線(xiàn)圈圈數不合格。<br /> 在儲線(xiàn)過(guò)程中，線(xiàn)圈可能發(fā)生擠壓移位，導致同一線(xiàn)圈在兩側鼓輪位置走線(xiàn)速度不同，這種情況會(huì )造成兩種問(wèn)題，一是出現線(xiàn)圈滯留堆積造成線(xiàn)圈張力不足，銅線(xiàn)無(wú)法切斷；第二個(gè)是走線(xiàn)速度過(guò)快導致內圈線(xiàn)扯外圈線(xiàn)，發(fā)生纏線(xiàn)的問(wèn)題。在繞線(xiàn)過(guò)程中，容易出現過(guò)程銅線(xiàn)走線(xiàn)分流不明確的問(wèn)題。此問(wèn)題也可能導致纏線(xiàn)的現象，即故障類(lèi)型二。<br /> <p> 從原理的分析可以得出繞線(xiàn)過(guò)程的實(shí)現主要依靠幾組轉輪組對線(xiàn)圈的摩擦力提供動(dòng)力勢能，輪組表面對線(xiàn)圈的摩擦力方向與線(xiàn)圈前進(jìn)方向一致。如圖8所示對繞線(xiàn)過(guò)程中鼓輪處銅線(xiàn)橫截面進(jìn)行受力分析，進(jìn)一步解釋故障問(wèn)題產(chǎn)生原因。 </p> <p> <img src="/upload/image/20200810/2020081012030742742.png" alt="" style="white-space:normal;" /> </p> F N 為輪組表面對銅線(xiàn)的支持力，f Z 為輪組表面對銅線(xiàn)的摩擦力，F 0 為銅線(xiàn)間的擠壓力。<br /> F N1 =- F N2 （1）<br /> fz = mF N = 2mF N1 （2）<br /> 由受力分析可知，銅線(xiàn)在Y軸方向受到上下支持力對其具有壓緊左右，在X軸方向受到相鄰線(xiàn)圈對其擠壓力F 0 ，這是線(xiàn)圈發(fā)生移位錯位的根本原因。<br /> 導致兩種故障類(lèi)型的問(wèn)題都出自于繞線(xiàn)機構部分的鼓輪。不難得出繞線(xiàn)機構即為所需優(yōu)化部分，尤其是兩側對稱(chēng)的鼓輪處。這是造成繞線(xiàn)良品率不高的根本原因。<br /> 3 繞線(xiàn)機內部結構優(yōu)化<br /> 3.1 微溝槽加工力學(xué)分析<br /> 確定在鼓輪上添加微溝槽來(lái)提高繞線(xiàn)良品率。工作原理為利用微溝槽壁對銅線(xiàn)的支持力消除銅線(xiàn)間的擠壓力，可以改善繞線(xiàn)過(guò)程中線(xiàn)的分布情況，從而調整銅線(xiàn)的速度，確保繞線(xiàn)過(guò)程中銅線(xiàn)張力足夠，實(shí)現較高成功率的繞線(xiàn)。<br /> 微溝槽加工需應用到微尖端加工技術(shù)。目前較成熟的微尖端加工技術(shù)為角度范圍在60°～120°的微尖端，本文將選取3種較常采用的方案進(jìn)行分析，即對加工60°、90°、120°的微溝槽角度這3種常見(jiàn)微溝槽進(jìn)行力學(xué)與加工可行性分析，最終確定微溝槽的加工角度。<br /> 設鼓輪與銅線(xiàn)間摩擦力為f，單個(gè)鼓輪的一個(gè)微槽對銅線(xiàn)的支持力為 F N 。3 種常見(jiàn)微溝槽力學(xué)分析如表 1 所示。在相同壓力條件下，隨著(zhù)微溝槽加工角度的增加，鼓輪對銅線(xiàn)的摩擦力逐漸減小。<br /> <br /> 該裝置實(shí)現了微型變壓器生產(chǎn)線(xiàn)上線(xiàn)圈繞線(xiàn)的自動(dòng)化，將企業(yè)微型變壓器的生產(chǎn)效率由20 pcs/h提高至95pcs/h。對裝置中鼓輪的優(yōu)化通過(guò)微溝槽力學(xué)分析及加工可行性分析，最終選擇了90°微溝槽作為加工方案�？梢詫�(shí)現將繞線(xiàn)機產(chǎn)出效率從95 pcs/h提高至170 pcs/h，并且同時(shí)解決磁圈間的銅線(xiàn)沒(méi)有切斷與在繞線(xiàn)時(shí)發(fā)生纏線(xiàn)這兩個(gè)問(wèn)題，提高了產(chǎn)品的生產(chǎn)效率。<br /><script src="/inc/AspCms_VisitsAdd.asp?id=345"></script> </div> <div style="width:950px; text-align:right; line-height:180%;" class="news_content_back"> <a 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