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Precise winding of self-adhesive coil with skeleton

Precise winding of self-adhesive coil with skeleton

 As shown in the figure below, it is a sensor coil used in the medical industry. The skeleton is made of aluminum. The diameter of the enameled wire is 0.1mm. The customer requires the arrangement to be neat and free of winding defects. The company has carefully evaluated the specific requirements of the customer, because the winding process and winding are considered. After the completion of the structure, the self-adhesive enameled wire process was adopted, and the self-adhesive coil winding machine was further optimized. The project was successfully completed. At the same time, some experience was summarized and shared with the public during the process.

           

      In recent years, due to self-adhesive support, self-adhesive coils do not need to be dipped in the later stage, which is convenient for industrialization. They have been widely used in deflection coils of precision instruments, combined coils in micro motors, and micro coils in sensors.

   Self-adhesive enameled wire has become the main wire type used in the coil winding process due to its excellent heat resistance, insulation, adhesion durability, easy forming, simple winding process and other advantages. After the self-adhesive coil is formed, it is required that the DC resistance of the coil is good, the inductance performance is stable, the wiring is neat and not scattered, the surface is smooth and there is no gap, and the appearance is beautiful.

In addition, the coil needs to maintain a certain shape during use, which requires that the bonding strength of the coil does not decrease over time under different environments. In the winding process, especially for enameled wires below 0.1mm, there are often scattered, overlapping, loose and other phenomena. The factors that affect the winding quality are mainly considered from the enameled wire, winding equipment and tooling:

 1 The influence of enameled wire on winding quality

The surface paint layer of the self-adhesive enameled wire is divided into two parts: a primer layer and a self-adhesive layer. The primer layer functions as an insulating layer and protects the internal copper core. The self-adhesive layer mainly plays the role of bonding and forming. The primer layer is formed mainly by dipping and baking, which is generally baked after two to three dipping. Both the primer and topcoat materials need to be filtered to filter gels and mechanical impurities. The solvent formula is reasonable, so that the wire coating can be cured smoothly without defects such as uneven thickness and bubbles. The uniformity, fluidity, and adhesion of the primer make the final film thickness uneven.

Take ELEKTRISOLA Ф0.06ABP15 self-adhesive wire as an example. The outer diameter is between Φ0.072mm and Φ0.075mm. According to actual experience, during winding, the wire spacing needs to be set higher than the diameter of the enameled wire. Enameled wire with a core material of Φ0.06 mm, and the spacing between the wires should be at least 0.08 mm. According to the bonding method, self-adhesive enameled wires are mainly divided into hot air, heating furnace, and alcohol bonding (soluble in absolute ethanol). Alcohol bonding is to directly bond self-adhesive enameled wires with industrial absolute ethanol (industrial alcohol, ethanol content is higher than 99%) when winding the coil. The limitation is mainly that alcohol has a swelling effect on self-adhesive materials, and there is excessive alcohol volatile concentration. High risk of spontaneous combustion or explosion, hot air or heating furnace method is convenient for mass production and automatic control. Therefore, the mainstream self-adhesive methods are mainly hot air, heating furnace and other heating methods. For thermal curing methods such as hot air and heating furnaces, the temperature of the heating process, the temperature gradient and the uniformity of the temperature have an important influence on the bonding performance of the winding. The bonding effect of self-adhesive enameled wire is mainly because the curing of self-adhesive paint is a staged polymerization process, at this time, the self-adhesive layer exists in the form of prepolymer. When the self-adhesive enameled wire is being wound, it needs to be heated (usually heated by hot air) to make it secondary polymerization and deep curing, so as to achieve the purpose of firm bonding.

REPOSAL winding machine continuous innovation to consolidate brand value

REPOSAL winding machine continuous innovation to consolidate brand value

Suzhou REPOSAL Electronic Mechanical Equipment Co., Ltd. is a technology enterprise specializing in R&D and production of winding equipment. For many years, it has insisted on maintaining innovation and researching and developing products with independent intellectual property rights.

  For quite a long time, my country's winding machine manufacturing industry generally has the problems of low technology, small scale, free and scattered production, and insufficient technological innovation of most enterprises. Compared with related industries abroad, my country currently has fewer types of winding machines and supporting equipment. The control technology used is relatively backward, and its accuracy and performance are not as good as those of their European and American counterparts. Moreover, the product has low production capacity and poor stability.

     In the face of technical gaps, Suzhou REPOSAL made a detailed market research and took the entire series of precision winding machines and Roche coil winding machines as breakthrough points.It valued cooperation with user companies and not only carefully understood the existing process requirements of customers. And through the company's accumulated technical database for many years, on the premise of no or little increase in costs, it actively provides new ideas and new solutions for customer process upgrades.In a specific single implementation case, this approach has undoubtedly aggravated us The execution cost of the company has reduced the company's profits, but this idea has been implemented and verified for a long time.In fact, our customers have tapped the potential of the coil winding process through our winding machine equipment and become our long-term cooperative customers. We have also accumulated more technical data for our research and development direction and solutions through proactive improvement of individual cases, so as to achieve continuous innovation.

 Electromagnetic coil precision winding machine for winding machine

Electromagnetic coil precision winding machine for winding machine

         Winding machine, when people talk about it, usually refers to a machine that uses enameled wire as a material to form a coil. In the impression, this should be a very simple machine or even some people's printing should be summarized as a simple Power tools. But in fact, this is an industry with a very wide variety, a wide range of coverage, and complex technical characteristics.

        From the processed products, such as the single-axis CNC winding machine for processing high-frequency transformer coils, the winding axis rotates, and the winding axis moves accordingly according to the set pitch. This is a relatively simple winding machine. For example, ordinary relays are characterized by the small diameter of the enameled wire and the relatively large number of turns, so the rotation time of the main shaft of the winding machine is long.The ordinary electromagnetic coil does not have too high requirements for the accuracy of the wiring, so the main requirement for the machine is the speed High and stable tension.

        Then there is the precision electromagnetic coil, which is also an electromagnetic coil, but because this coil has temperature resistance requirements, response speed requirements, wire package volume requirements, and product consistency requirements, it is required that the winding machine be wound during winding. Each wire is neatly arranged, so to achieve this accuracy, there are strict requirements for all process factors in the winding process.

        There is the rotation accuracy of the winding spindle of the winding machine. The control accuracy of the winding machine controller, the repeating positioning accuracy of the wire screw, the roundness of the enameled wire, the diameter of the enameled wire, the rotation of the tooling behind the main shaft of the winding machine Accuracy, tension control of the enameled wire, parallelism of the two ends of the cable cavity during winding, dimensional accuracy, and also includes the structural design of the cavity during cable routing, and the design of stripping after winding. It is directly related to the success of the winding accuracy.
Tension control of precision rectangular coil winding machine

Tension control of precision rectangular coil winding machine

      This article introduces the test of designing tension control system to minimize the change of tension. Perform theoretical analysis on simulation. The simulation results show that the tension of the enameled wire is frequently fluctuated due to the length change caused by the speed change. The model's tension sensor verifies the prediction. The key to successful design is to eliminate changes in tension. We added a tension system that includes a high-speed cylinder to replace the traditional wool felt and spring mechanism. The simulation results showed that the new prototype system almost doubled the winding speed and the ability to withstand tension fluctuations.

          



Keywords: tension control, winding machine, rectangular coil, precision winding machine.


One. introduction


      Countless transformers are produced every year. Together with power plants, substations and power lines, distribution transformers provide electricity for businesses and residential buildings across the country. Transformer manufacturing involves the production of winding coils. These coils are usually made of an insulating paper layer sandwiched between a pair of copper wires. They are usually round or rectangular.


      A consistent tension must be maintained on the coil windings. The shape of the coil has a major influence on the tension applied by the tension. For a circular coil, the tension does not change significantly, but a rectangular coil is different. As a rectangular coil, the tension changes sharply with the position of the drop point. As shown in the figure, this change in speed is caused by the changing length of the line. In the case of a round coil, this is not a problem, because the contact points of the wires on the coil are fixed.



Precision C-shaped coil winding machine

Precision C-shaped coil winding machine

Precision C-shaped coil winding machine

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