The Mechanical Design And Control Of Coreless Coiling Machine

With the advance of various industries, the electromechanical device's strict technical conditions have higher and higher requipments on the technology of servo motor. Due to the property that normal motors can not transcend, coreless motors have been used more and more in many areas, such as military affairs, high-teach area and daily life. The manufacturing process of motor's coil is a very important issue in motor production. We need to develop a automation equipment which can be used in the manufacturing process of motor's coil.There are three methods to make coreless motor coils: diagonal-line manner,straight-line manner and broken-line manner. Since star-shaped coils provided low-phase voltage and the advantage of smooth start-up applying to micro motor. Our final objective is to make a micro coreless motor. We are committed to achieve automatic equipment that can produce different coreless coils. The characteristics of the equipment can complete all the winding methods and it has a lot of advantages such as high efficiency precision wire laying and high versatility.In accordance with the requirements of the target, we analyze the coil winding principle and the realization of automation equipment, determining the overall shceme of the winding machine. In order to achieve the requirement, we finished the overall control scheme design of the winding machine according to the coil winding way.Using three-dimensional software we completed the detailed mechanical structure design.Then we finished the statics analysis, fatigue analysis, modal analysis to the key components of the winding machine using Ansys workbench. We get the stress and strain contours, fatigue life contours, modal shape contours of the key parts of the mechanical structure. After the finite element analysis, the result indicated that the winding machine frame had good dynamic characteristics and also reduced the cost of product. It makes sense to the proper functioning of winding machine optimizing the weak place. We finished the virtual simulation research of the winding machine was made by three-dimensional software.According to the requirement of the overall scheme,we design and simulate the control system. Then its electrical control system ws designed and built. The external circuit design of master controller, drive and attemperator were also introduced. The matlab/Simulink software tool is used to design and to simulation model of AC servo motor and synchronous belt. The design of closed-loop controller and belt drive are validated by the simulation result.Finally, we completed the assembly interference model and movement simulation. We built the experimental model and control system, verifing the rationalization of winding machine movement, system stability and accuracy by making a coil. Compared coil parameters to target parameters, we verify that the coils were able to meet the needs of use,and the winding machine can realize the expected function.