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CNC Servo 4 Arm Coil Forming Machine For High Voltage Motor

Overview
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CNC Coil Spreading & Forming Machine-Servo

(Four arm column)

I Description of the machine

This machine is used for spreading bigger and middle size of coils, such as longer prismatic of big motors or bigger section of motors, which is consist of main transmission system, hydraulic system, servo system, electric control system, top arc system, and automatic control system coordinated by each system.

Process chart:

Adjust the size as needed - turn on machine - equipment automatically runs to the zero initial state - input parameters - confirm - put the coil - press the start button - clamp the coil - forming - loosen the clamping tool- remove the coil by hand - equipment back to the selected initial state - press the start button to enter into next coil forming cycle.

II Usage and characteristic

Adopt electric and hydraulic linkage technology to automatically and continuously complete the coil expanding process from shuttle shape to finished product. The molding precision is high to avoid insulation damage caused by knocking the coil during the molding process. A servo is used to realize the lifting and lowering of the pressure plate, and two auxiliary devices are used to realize the opening and closing of the grinding tool.
Continuous and single-step operation modes are suitable for both mass production and prototype trial production.
It has unique fusiform shaping and centering functions to obtain good straight edge status and end symmetry. The split model consists of a fixed bed and a movable bed.
This machine is widely used for drawing the stator frame coils of large and medium-sized motors with extended coils and long prismatic shapes or large and medium-sized motors with larger cross-sections.
The control system of this machine is operated manually.
The working pressure and stroke of this machine can be adjusted within the specified range according to process needs, and can complete the fixed-stroke process method.
The screw rod on the work surface is pushed and pulled, and the loading and unloading operation is convenient, the positioning is accurate, the press installation is balanced and reliable.

III Design and technical

Before forming( picture 1)

After Forming (picture 2)

Machine code	WXT-2000
Coil size before forming
The length before forming, L1	700-3200mm
Pitch range before forming, L2	600-3100mm
Circle radius of coil nose ,R	15-30mm
The width of coil, A	5-23mm
The height of coil, B	20-65mm
Coil size after forming
Straight edge length, L3	280-2000mm
Total length of coil, L4	450-2500mm
Total width of coil, W	100-750mm
The elevate range for nose, H	20-300mm
Angle of inclination of coil nose θ1	0-30°
The coil upper edge and the angle of center lineθ2	Max. 65°
The coil lower edge and the angle of center lineθ3	Max. 65°
Coil nose R	R7.5 R15 R20
The circular arc radius of straight side and hypotenuse R4	R20 R30 R40
The circular arc radius of coil nose and hypotenuse R3	R15 R25
Spreading accuracy	±0.2mm
Working voltage	380V, 3Phase, 50Hz.
Environment temperature	-5-40℃
Relative humidity	≤95%

IV Equipment working requirement

●Floor space: 6500 x 1630 x 1900mm

●Main driver method: Servo

●Parts driven method: Ball screw

●Clamp method: Oil cylinder

●Voltage: 380V, 3phase, 50Hz

●Spreading speed: 1-6 min for one coil (adjustable),

●Total power: 22kW

Hydraulic oil cylinder	Φ50 x 150㎜
Clamping size	7-60mm
Hydraulic motor	7.5kW
Spreading accuracy	Angle ±0.5 degree Span is less than ±0.25mm- ±0.75 mm
PLC	Mitsubishi
Cylinder	AirTAC
Main electrical element	Schneider
Button	SANLI
Sensor	Omron
Servo motor	750W x 15

V Equipment composition

Main drive system, hydraulic system, servo system, electrical control system, Arc forming system, and automatic control system for coordinating all these systems.

VI System Composition and Principle

1. The main transmission adopts servo mode, and the clamp adopts oil cylinder and regulating valve, which can ensure the accurate positioning of each station;

2. The four-arm stretch adopts servo plus ball screw drive, which has the characteristics of accurate positioning and high precision.

3. Wide applicability: It can complete the expansion of all stator coils.

4. Reasonable structure: The gears and rotation angles can be adjusted separately, with high degree of automation, simple and convenient operation, reliable safety performance, simple maintenance, continuous operation, good stability and high production efficiency.

5. The forming parameters of the coil forming process of the entire equipment are programmed through a microcomputer. After manually installing the wound coil, the equipment can automatically control the automatic operation of the nose clamp and linear clamp by pressing the start button. The length and angle of the straight line part of the coil coil, the top arc of the end and the automatic operation process of the nose height can be automatically completed in sequence according to the program. After the coil is expanded, the clamp is automatically released, the coil is manually removed, and the equipment status is automatically reset. Meet the drawing and process quality requirements of the coil. Equipment should be easy and quick to adjust.

6. CNC servo is used to control the opening of the coil and the angle of the coil. The precision is good, and the adjustment is convenient on the touch screen.

7. The coil has automatic distance and centering functions to ensure that the coil meets the design requirements.

8. The expansion principle and trajectory of the equipment move around the center of the circle, and the synchronization ensures that the spans at both ends are consistent and can be accurately embedded in the motor slot.

9. After the expansion, the coil opening, angle, nose height and arc are controlled accurately.

10. The top arc system at the end of the equipment adopts the multi-Allegro splicing type, and different arcs are manually assembled to ensure the expansion requirements of the coil ends of different specifications.

11. There is no mechanical damage to the expanded coil, and the inter-turn insulation of the coil is intact to ensure the reliability of the electrical performance of the coil.

12. All processes except loading and unloading of workpieces are fully automated.

13. The design shall be carried out in strict accordance with the national standards on labor safety, sanitation, fire protection and environmental protection.

14. The equipment is elegant in appearance, meets the requirements of product use, reliable in operation, easy in operation, and convenient in maintenance.

15. The control system fully considers the interlocking nature of the systems, and has taken protective measures in terms of resistance and other aspects to avoid equipment accidents.